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SM-6263A - Ansaldo STS

1. Motor Cutout Contacts 49 and 50 Slate o 5 9 o 5 242582 ODE o m o 9020 gt o oo TES pi ee See 2 383 e S aa 3 9 gt 00000 Sp OOo gt 5 S Q00000 Bal 5 Ss a E oS 292898020 SEN 8 8 50 ep 5s9s 5 zee d ES oS 9 38 ESSE 3 og mou o d SS n 25 Sr pr Ez 55 Ms x u 2 H Es Motor End 003 IWNOIS 9 HOLIMS MOND Lock Sensor 1 Lock Sensor 2 View A Proximity Sensor Layout amp Identification 19619 Red Reverse l Remote 3 o a Ei sa EE O O o O O BIG CC oOJojo 9 BIG OIDO BEE O Q A A Yellow Green LA Installation WARNING Maintenance Bi Polar Terminals 21 and 23 are Non Vital and should never be used to clear signals A WE TE EE 9 1OIOIOIO DAMOJ Oo O I QIAI BD BO O O BE O O DIO QO OO ve M 0000000000 000 e AE a Das Da Ds De hs hs Co a C2 GERI IO olo QIO OOmamaaaanmMa amam O CO CECI CE C O 9 LI O e C elle e o ci Peng e er N se hd lh ss o DIS TUB S gu 1 I UJE
2. SS o STOP SCREW Ju WHEN USED lo DIAGRAM C L H LAYOUT L H POINT NORMALLY CLOSED LEVER INTERLOCK F ASSEMBLY STEEL BALL STOP SCREW WHEN USED dn 0000 DIAGRAM D R H LAYOUT R H POINT NORMALLY OPEN Figure 4 7 Standard Lever Interlock Assemblies for M 23 Switch Machine SM 6263A Rev 3 November 2010 4 19 AY Installation d AnsaldoSTS 4 8 2 Lever Assembly For the removal and insertion of the lever assembly ASTS USA recommends that two men perform the procedure one to insert the lever assembly and one to hold and guide the hand throw bevel gear onto the lever assembly shaft If only one person is available ASTS USA recommends dismantling the lever assembly to move it to the other side of the gearbox 4 8 2 1 Disassembly l Remove the 7 8 hex nut lock washer and flat washers from the end of the selector lever shaft and slide the selector lever from the shaft Be careful not to lose the steel ball in the lever support Lift the hand throw lever to the vertical position and loosen the set screw F1 on the hand throw bevel gear F Remove the hand throw lever from the lever shaft Remove the two 1 2 13 x 4 3 4 bolts A3 and lock washers that secure the lever support K to the gearbox and slide the lever support fr
3. A FOR MOTOR CONTROL UNIT SUFFIX 06 CONNECT WIRES 5 8 6 TO WAGO TERMINALS 32 AND 34 AS SHOWN CONNECTIONS PROVIDE ACCESS TO RELAY INDICATION CONTACT INSIDE MCU REMOVE GROUND WIRE IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY REFERENCE DRAWING F422152A Figure 4 11 Internal Wiring Diagram Low Voltage Control Unit with Permanent Magnet Motor SM 6263A Rev 3 November 2010 4 29 30 RY e AnsaldoSTS UG0106 0039 01 Auxiliary Sensor 1 Auxiliary Sensor 2 Point Sensor 1 Point Sensor 2 Lock Sensor 1 Lock Sensor 2 2 LOCK POINT AUX 2 2 BU BR BU BR BU BR BU BR BU BR BU BR LOCK POINT AUX 1 m BLACK Se BROWN me RED ul 3 ORANGE g 4 YELLOW g 5 GREEN 16 BLUE a 7 VIOLET L1 8 GRAY ul 9 WHITE C 10 BLACK WHITE Ot BROWN WHITE 12 RED WHITE o 13 ORANGE WHITE o 14 YELLOW WHITE g 15 C LL JUNCTION BOX N42400801 o A N42400802 Tape lead to harness only for 115V source for field applications with 115V source disconnect 7 for 230V and connect this lead to terminal 7 combine 49 50 and conneet Slate Mi A MN El Ll of to terminal 48 y i Lj 8 Oo O DB gogo A Heater E Violet E O NI El E Green Yellow Top View to terminal 7 White 1 O o kl XA Brown E O O s
4. 3 4 SM 6263A Rev 3 November 2010 RN e AnsaldoSTS Functional Description Table 3 1 LED Diagnostics Switch Sensor On Point Detected Red Sensor Off Flashing Red Green Indeterminate Sensor On Point Locked Red Sensor Off Flashing Red Indication Indeterminate Indication input power present from adjacent machine Input Indication No indication power present Switch is locked and detected indication output is on Output Auxiliary Point Switch is not locked and detected indication output is off Aux sensor on aux bipolar output is on Detected Aux sensor off aux bipolar output is off Latched out Latch out Motor Not latched out Motor power disabled Disabled SM 6263A Rev 3 November 2010 Motor power enabled 3 5 A Functional Description 7 AnsaldoSTS Ny Y AnsaldoSTS 3 6 SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation 4 INSTALLATION To avoid severe personal injury open the gold nut test link in the motor compartment prior to performing any internal machine maintenance Always keep hands and feet clear of switch points and the internal moving parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine 4 1 Junction Box Jumper Configuration 4 1 1 RHPC LHPC Jumpers All right hand and left hand M 23 switch machines are config
5. N o IDI y wo A a UG0106 0037 01 JUNCTION BOX N42400801 OR N42400802 1 Point Sensor 1 Point Sensor 2 2 Auxiliary Sensor N47303401 O Point Detected Point Locke VO O Point Locked Indication Input O O Indication Input Indication Output O O Indication Output Auxiliary Point Detected O Ol Auxiliary Point Detected O Y LED Diagnostics PointDetected Latch Out Motor Disable UNION SWITCH amp SIGNAL ECC Latch Out Restoration Press for 1 Second and Release Bk JB1 EN Motor Cutout Contacts 49 and 50 WARNING Maintenance Bi Polar Terminals 21 and 23 are Non Vital and should never be used to clear signals Counter TB2 TB1 SS 99 1VNBIS HO IMS NOINN Ms N Motor End Lock Sensor1 Lock Sensor 2 View A Proximity Sensor Layout amp Identification Auxiliary Sensor 49 iliis 50 Slate O s LI o o 8 oo Blue Bello Violet MN o O sl MN G4 Green Yellow White Qo OE e O 9 LI L Black ijJolljolLlltli lo 1 3 Un l
6. Item No Description ASTS USA Part No 6 Sensor Holder M42370202 8 TerminalPost M130599 9 Belleville Washer Serrated 5 16 J4751200169 6 8 SM 6263A Rev 3 November 2010 Ei e AnsaldoSTS Parts List Figure 6 4 Point Detector Sensor Assembly SM 6263A Rev 3 November 2010 6 9 RN Parts List d AnsaldoSTS 6 6 Motor Compartment Assembly Table 6 8 lists the parts of the motor compartment assembly and Figure 6 5 shows the parts location Table 6 8 Parts List for the Motor Compartment Assembly ItemNo Description ASTSUSAPartNo 60 Washer Lock 3 8 Steel JO47768 Screw 3 8 x 6 7 long Skt Cap Sleeve AAR Mounting Tag 1 111 1211 8000333 Washer 3 8 Lock Extended Countersink J4751430002 6 10 SM 6263A Rev 3 November 2010 Parts List e AnsaldoSTS VIEW OF SURGE SUPPRESSOR PCB EXISTING BASE 5 Motor Compartment Assembly Figure 6 6 11 SM 6263A Rev 3 November 2010 RN Parts List d AnsaldoSTS 6 7 Terminal Assembly N42270301 Table 6 9 lists the parts of the terminal assembly and Figure 6 6 shows the parts location Table 6 9 Parts List for N42270301 Item No Description ASTS USA Part No Assembly 8 Way AAR Terminal Permanent Magnet Motor eese Screw 10 32 X 3 4 Stainless Steel J5001240014 Nut 1 4 20 Stainless Steel Elastic Stop Nut J480260 AAR Mounting
7. R FRICTION CLUTCH 2ND REDUCTION GEAR 1ST REDUCTION GEAR Figure 4 6 Sectional View of Gearbox Looking from Motor End SM 6263A Rev 3 November 2010 4 15 AY Installation d AnsaldoSTS 9 Liftthe hand throw bevel gear F from the gearbox 10 Remove the 1 2 13 x 6 bolt G 1 2 nut and two lock washers securing the yoke eccentric bushings G1 to the yoke support H The positions of the eccentric bushings should be noted and care should be taken to avoid changing their position when removing the bolt 11 Remove the four 1 2 13 x 1 1 2 bolts and lock washers which secure the yoke support H to the gearbox and remove the yoke support NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused 4 8 1 2 Reassembling 1 4 16 With the gearbox disassembled per Section 4 8 1 1 grasp the yoke N firmly and lifting upward rotate the yoke 180 Be sure the yoke assembly seats firmly on the main shaft after it is moved Transfer the yoke support H to the other side of the gearbox Insert it into the gearbox and secure it with the four 1 2 13 x 1 1 2 bolts and lock washers removed in Step 11 of Section 4 8 1 1 When inserting the yoke support into the gearbox be careful not to disturb the positi
8. a Normal indication input is defined between Terminals 13 and 15 15 being positive and 13 being negative b Reverse indication input is defined between Terminals 10 and 12 12 being positive and 10 being negative c Ifthe machine is used in a single machine application battery must be fed to the Indication Input circuits to provide indication output Refer to Section 4 2 for proper jumper configuration SM 6263A Rev 3 November 2010 4 9 N gt Installation AnsaldoSTS NOTE Four indication input jumpers are factory installed on the WAGO terminal strip and must be removed for multiple machine applications 5 Terminal 17 is used for connecting wayside battery N12 Terminal 20 is used for connecting wayside battery B12 Note that there are factory installed jumpers between paired Terminals 16 and 17 and between paired Terminals 19 and 20 Wayside battery can be fed to either available terminal of each pair 6 Terminals 21 and 23 are for field connections to the two wire bipolar auxiliary sensor output a Normal auxiliary indication is defined as on Terminal 23 and on Terminal 21 b Reverse auxiliary indication is defined as on Terminal 23 and 4 on Terminal 21 The maintenance output is not vital and should never be used to clear signals 7 Terminals 24 25 and 26 are for field connections to utilize the local remote request switch option This function will be partic
9. 4 8 1 2 ReasseMbling usoa nee e der 4 16 SM 6263A Rev 3 November 2010 iii AY Table of Contents d AnsaldoSTS 4 8 2 Lever Assembly EA a ree ee ee eeu dee ed ene ANAO 4 20 48 24 DISaSSemBlV i AM nq tete edes 4 20 4 8 2 2 Reassemblys y sia Seege geed bates EE ete das 4 20 4 8 3 Other Mechanical Changes A 4 21 4 3 3 1 Operating Baf smo Aa 4 21 4 8 4 Selector Clutch Adusiment coco norncn anna 4 22 4 8 5 Jumper Configuration Changeover ui 4 22 4 9 Final Inspection and Testing after Installation o ooconnnnicnnnnnccnn nncccnnnancccnnnancccnnnarccnnnancccnnno 4 23 5 TROUBLESHOOTING icc EE 5 1 6 5 PARTS LISTS lt a 6 1 6 1 Circuit Controller Compartment A 6 2 6 2 Circuit Controller ECC Assembly N422529 XX nennen 6 4 6 3 Junction Box Assembly N42252701 sse eee 6 6 6 4 Point Detector Sensor Assembly Without Auxiliary Sensors N42252401 6 8 6 5 Point Detector Sensor Assembly With Auxiliary Sensors N42252402 6 8 6 6 Motor Compartment Assembly sse nennen nnne nennen nnns sn tenens 6 10 6 7 Terminal Assembly NA 0201 6 12 6 8 WAGO Assembly N42270401 ei 6 12 6 9 Sensor Use ice TTT rm nei Fen ecd ITT PTT TTT 6 15 7 RAIL TEAM AND TECHNICAL SUPPORT rnnnannnnnnnnnnvnnnnnvnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 7 1 iv SM 6263A Rev 3 November 2010 Ansaldo
10. o U eT Se WAGO Ground Stud ololololololololololololslole olotololololololololala Black TL 4 Local Request Normal Request Reverse Request Maintenance Bi Polar Normal Ground Terminal Maintenance Bi Polar Normal Battery Input B12 Ground Terminal Battery Input N12 Normal Input Ground Terminal Normal Input Reverse Input Ground Terminal Reverse Input Normal Output Ground Terminal Normal Output Reverse Output Ground Terminal Reverse Output Bi Polar Normal Ground Terminal Bi Polar Normal To AAR Terminal 2 Earth Ground Motor Control Unit Retrofit i Machine N473039 02 low voltage 360 1 and Or 528 1 N473039 06 low voltage gear ratio AAR Terminal Block 1 Red CC Lo A Black Ne ack Connection To WAGO 195 Ground Stu Motor Cutout D Contacts Machine Fe Frame 51 e O OJ Gold Nut Ne S gt Heater Terminals 8 Permanent Magnet Motor Configuration MR Fee Sene Fr A ETT E 1 ASSEMBLE AND TEST PER EU 8557 CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE CORRECT WITH 360 1 8 528 1 GEAR RATIOS CONNECT WIRE 1 TO WAGO TERMINAL 30 amp WIRE 2 TO WAGO TERMINAL 29 FOR 189 1 GEAR RATIO N42400801 JCT BOX W O SEALING PLUGS TO BE USED WITH AUXILIARY SENSORS N42400802 JCT BOX W SEALING PLUGS TO BE USED WITHOUT AUXILIARY SENSORS A INDICATED POLARITY DRIVES POINTS RIGHT SEE VIEW A
11. 2 Black JS OSD etn e Normal gt Lo L e O U Local Jo EI IDG O Local Request Homote 2 o Li s O Normal Request a E lo O B o Reverse Request flo s AA J o Maintenance Bi Polar Normal s Lo Ground Terminal Green s O Maintenance Bi Polar Normal 4 o U s O Battery Input B12 Black 2 N47303401 lH Lj 38 Ll E O Ground Terminal 582 di LI EES 5 2 o El ss TT ol Battery Input N12 EE o Yellow 2 F1 E 3 FE P a Black L 2 LI El RLE a x 2 6 x Ni s b Normal Input e eRe S E El O Ground Terminal 00000 Ba 5 Ss Brown E r1 _ 9228 338 5 85 a mm E Ll L C Normal Input 88 d8so 9 g F EI O Reverse Input ot Oo t SE 2 F l LI ee L O Ground Terminal set a e EO O Reverse Input gum ellow E E 3 U e O Normal Output S 0 9 Ground Terminal gr e H E O Normal Output ue z Motor End E 3 e Reverse Output Auxiliary Sensor 1 H c O Ground Terminal Point Sensor 1 SC I O Reverse Output e Point Sensor 2 2 gt i Auxiliary Sensor 2 E B O Bi Polar Normal 8 O Ground Terminal n O TT O Bi Polar Normal View A Proximity Sensor Layout amp Identification Motor Cutout Contacts 49 and 50 WARNING Maintenance Bi Pola
12. Detector Sensor Assembly sse rennen 6 9 Figure 6 5 Motor Compartment Assembly ssssssssssssseseeeeeen rennen rra 6 11 SM 6263A Rev 3 November 2010 V vr 3 Table of Contents 7 AnsaldoSTS List of Tables Tablet LED Diagriostics uid edat ee tae AG der da Een 3 5 Table 5 1 ECC Troublesbooting AAA 5 1 Table 6 1 Various Available ECC Configurations nennen 6 1 Table 6 2 Parts List for the Circuit Controller Assembly NA22bO0o XVI 6 4 Table 6 3 Parts List for the Circuit Controller Compartment canaria 6 2 Table 6 4 Parts List for the Junction Box Assembly A 6 6 Table 6 5 Wiring Chart for the Junction Box Assembly Hamess ieee 6 6 Table 6 6 Parts List for the Point Detector Assembly AA 6 8 Table 6 7 Parts List for the Motor Compartment Assembly sse 6 10 vi SM 6263A Rev 3 November 2010 AY Ei AnsaldoSTS Introduction 1 INTRODUCTION 1 1 Introduction This service manual describes the integration of the Electronic Circuit Controller ECC into existing M 3 and M 23 switch machines For detailed information on the installation operation maintenance and adjustment of the M style machines please refer to Service Manual 6263 1 2 Applications 1 2 1 ASTS USA Electronic Circuit Controller The ASTS USA Electronic Circuit Controller ECC is designed to be applied to both the new ASTS USA M 23E style switch machine and existing M style machine
13. and BL for blue B Sensor air gap not 1 For vital large diameter sensors ensure gap properly adjusted between sensor face and PD target lock box is adjusted to 0 075 and the gap from the sensor to the lock box target is 0 075 2 For auxiliary non vital small diameter sensors ensure that the air gap between sensor face and target is adjusted to 0 040 Point Detected and Point A Indication Input is not 1 Ensure Indication Input voltage with proper polarity is Locked LEDs are energized present on WAGO Terminals 13 and 15 for Normal GREEN but Indication and Terminals 10 and 12 for Reverse Voltage should Output LED is dark be obtained from an adjacent machine or jumper connected per Section 4 of this manual B The ECC is in 1 Reset the latch out by depressing the latch out latched out state restoration button on the front of the ECC holding for one second and releasing C Motor is DISABLED by In M 23 with ECG rotate the selector lever to EGG Red Motor the Motor position The light should go dark on Disabled LED is ON the motor cutout and the indication output LED should come on D Point and or Locking In an M 23 equipped with an ECC ensure the sensor for opposite two wires connecting motor cutout contact to switch machine WAGO terminal strip are connected properly position are ON and that the 750 ohm resistor is properly installed between WAGO Terminals 33 and 34 5 2 SM 6263A Rev 3 No
14. bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused Secure the lever shaft bearing M to the gearbox case using the two 1 2 13 x 1 1 2 bolts A4 that were removed in Step 4 of Section 4 8 2 1 Put the hand throw lever on the lever shaft The lever is keyed to the shaft and can be put on in either direction Be sure it is positioned on the shaft so that it moves in the proper direction Slide the lever support K onto the lever shaft Secure it to the gearbox case with the two 1 2 13 x 4 3 4 bolts A3 and lock washers removed in Step 3 of Section 4 8 2 1 Put the selector lever onto the lever shaft The lever is keyed to the shaft and can be put on in either direction Be sure it is positioned on the shaft so that it moves in the proper direction Secure the selector lever to the shaft with the 7 8 hex nut lock washer and flat washers removed in Step 1 of Section 4 8 2 1 Other Mechanical Changes 4 8 3 1 Operating Bar l Remove the two operating bar covers from either side of the switch machine by removing the 1 2 bolts and washers that secure it to the machine These have to be installed on the other side of the switch machine when the lug is installed Remove the cotter pin the 7 8 nut washer and 7 8 9 hex head bolt which secure the operating bar lug to the operating bar Rem
15. from ASTS USA with these jumpers installed and must be removed for multiple machine applications Referring to the wiring diagrams in Figure 4 10 Figure 4 11 and Figure 4 12 four jumpers must be installed Terminal 16 for N12 is connected to Terminal 13 normal input which is also jumpered to Terminal 10 reverse input Terminal 19 for B12 is connected to Terminal 15 normal input which is also jumpered to Terminal 12 reverse input With the above jumper configuration in place both green LEDs for indication input will always be illuminated in the ECC box to indicate continuous power is being supplied to the indication input circuits 4 2 SM 6263A Rev 3 November 2010 e AnsaldoSTS Installation 4 2 2 Multiple Machine Setup If the machine is the first machine in the crossover i e the indication output is not dependent upon the indication input from an adjacent machine the indication input circuits are to be jumpered as described in the above paragraph for a single machine application If the machine is the second machine in a crossover application 1 e requires indication input from the first machine to properly deliver indication output to the wayside indication input jumpers are not used The indication input circuits of the second machine are to be fed from the indication output of the first machine to ensure that both machines in the crossover are locked and detected in the correct position S
16. pairs and each of the two paired sensors one point and one lock are ANDed linked together To receive a normal switch indication output from the ECC both the point and lock sensors for the normal position must both be energized or ON The same is true for both point and lock sensors for the reverse position If either one of the two paired sensors is OFF in either switch position the switch indication output is OFF for that position The paired sensors are labeled PS1 and LS1 and PS2 and LS2 Which pair of sensors corresponds to the normal position is dependent upon the position of the LHPC RHPC jumper position in the junction box refer to Figure 3 1 When the machine is locked and the points are detected in either the normal or reverse positions illustrated by the point detected and point locked LEDs and the corresponding indication input is present or energized the indication output LED for that switch position will be illuminated on the ECC This is a direct confirmation that indication power approximately 12 VDC is leaving the machine 3 1 1 Latch Out If the machine is locked and detected in either the normal or reverse positions and the points move away from the stock rail the ECC will electronically latch out turning OFF the indication output for that position and holding it out in a manner depending on the latch out jumper position in the junction box A latch out condition is indicated by the illumination of the RED La
17. set screw F1 on the hand throw bevel gear F 7 Remove the two 1 2 13 x 4 3 4 bolts A3 and lock washers that secure the lever support K to the gearbox Remove the two 1 2 13 x 1 1 2 bolts A4 and washers that secure the lever shaft bearing M to the gearbox 8 Holding the levers securely and guiding the shafts from the gearbox carefully remove the lever assembly from the gearbox Hold the hand throw bevel gear so that as the lever shafts are removed the bevel gear doesn t fall onto the bottom of the gearbox CAUTION Removal of the lever assembly requires two persons to perform the procedure one to remove the lever assembly and one to hold the hand throw bevel gear to prevent it from falling into the gearbox as the lever assembly is removed NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused 4 14 SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation A2 TOP VIEW R O LEGEND FOR FIGS 4 5 amp 4 6 A1 BOLT A2 BOLT A3 BOLT A4 BOLT B1 NUT B2 WASHER C BEARING C1 KEY C2 BEARING BUSHING D PINION E COLLAR F GEAR F1 SET SCREW G BOLT G1 YOKE BUSHING H YOKE SUPPORT Ai N C1 RIGHT HAND SIDE K LEVER SUPPORT VIEW M BEARING N YOKE P PIN
18. the machine as indicated for standard assemblies in Diagrams A B C or D Figure 4 7 the selector lever and lever interlock must be reassembled 180 from the original position on the shaft as follows a Remove the 7 8 hex nut lock washer and flat washers from the end of the selector lever shaft and slide the selector lever and lever support K from the shaft Be careful not to lose the steel ball in the lever support NOTE If the stop screw is used in the hub instead of the hand throw lever it will be necessary to also remove this lever and interchange the stop screw and cap screw refer to Figure 4 7 Replace the hand throw lever and fasten it in place with the clamping bolt b Reassemble the lever support K with the hole for the steel ball on the motor side of the shaft Insert the steel ball and reassemble the selector lever on the shaft so that the lever is 180 from its original position The stop screw if used may require positioning the hand throw lever to align the recess with the hole in the lever support so that the steel ball will not interfere when the selector lever is applied c Replace the hex nut and washers on the end of the shaft to hold the selector lever in place then secure the lever support K with the two 1 2 13 x 4 3 4 bolts A3 and lock washers removed in Step 7 of Section 4 8 1 1 These bolts also secure the bottom of the lever shaft bearing 8 Move the selector lever to the Moto
19. the bar out of the machine SM 6263A Rev 3 November 2010 4 1 Sy Installation 74 AnsaldoSTS 4 Remove the two Allen head countersink screws securing the PD target guard underneath the PD bar area 5 Remove the two hex bolts securing the circuit controller frame near the gearbox 6 Unfasten the cable wire restraint holding ECC cables TB1 and TB2 7 Remove the controller frame assembly to access the junction box located on the left side of the controller frame looking into the gearbox 8 Remove the junction box cover by removing the four screws at the corners of the cover 9 Change the jumpers to the desired configuration RHPC LHPC and or Latch Out jumpers Figure 4 1 shows the location of the jumpers on the junction board in the junction box 10 Replace the junction box cover and resecure the controller frame assembly 11 Insert the point detector bar and secure the target using the hardware removed in Step 3 12 Reconnect TB1 TB2 and JB1 plug connectors 4 2 ECC Power and Indication Input Setup The ECC requires a continuous wayside battery feed of 12 VDC connected to WAGO Terminals 17 N12 and 20 B12 Indication input can be set up either for a single machine such as an end of siding application or multiple machines such as a daisy chained crossover 4 2 1 Single Machine Setup The indication input to the ECC must be jumpered on the WAGO terminal strip to receive continuous battery feed The ECC is shipped
20. 0 1 GEAR RATIO CONNECT WIRE 1 TO WAGO TERMINAL 29 amp WIRE 2 TO WAGO TERMINAL 30 A N42400801 JCT BOX W O SEALING PLUGS TO BE USED WITH AUXILIARY SENSORS N42400802 JCT BOX W SEALING PLUGS TO BE USED WITHOUT AUXILIARY SENSORS A INDICATED POLARITY DRIVES POINTS RIGHT SEE VIEW A REMOVE GROUND WIRE IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY REFERENCE DRAWING F422152 Installation Figure 4 10 Internal Wiring Diagram High Voltage SM 6263A Rev 3 November 2010 4 27 28 RY e AnsaldoSTS UG0106 0038 01 Auxiliary Sensor 1 Y Auxiliary Sensor 2 Point Sensor 1 Point Sensor 2 Lock Sensor 1 Lock Sensor 2 2 LOCK POINT AUX BU BR BU BR BU BR BU BR BU BR BU BR LOCK POINT AUX BROWN ORANGE YELLOW WHITE RED WHITE o ON Om k CO MW eh Zeit eh D c AS ORANGE WHITE YELLOW WHITE JUNCTION BOX N42400801 OR N42400802 Auxiliary Sensor 1 Point Sensor 1 Point Sensor 2 Auxiliary Sensor 2 Tape lead to harness ol nly for 115V source for field applications wi h 115V source disconnect 7 for 230V and connect this lead to terminal 7 Heater Top View Combine leads and connect to terminal 8 Connnect lead to terminal 7 s N47303401
21. 09 N42307007 N42307004 N42250005 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250006 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250007 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250008 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250009 M 3 ECC N42307001 N42307002 N42307008 N42307009 X X N42250010 M 3 ECC N42307001 N42307002 N42307008 N42307009 X X N4225001 1 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250012 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250017 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250018 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250019 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250020 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250101 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250102 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250103 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250104 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250105 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250106 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250107 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42
22. 307004 N42250108 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250109 M 23A ECC N42307001 N42307002 N42307008 N42307009 X X N42250110 M 23A ECC N42307001 N42307002 N42307008 N42307009 X X N42250111 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250112 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250115 M 23A ECC N42307001 N42307002 N42307008 N42307009 X X N42250116 M 23A ECC N42307001 N42307002 N42307008 N42307009 X X 6 15 N ki uw AnsaldoSTS Parts List MACHINE TYPE LOCK 1 LOCK 2 POINT 1 POINT 2 AUX 1 AUX 2 N42250117 M 23AECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250118 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250119 M 23A ECC N42307001 N42307002 N42307008 N42307009 X X N42250120 M 23AECG N42307001 N42307002 N42307008 N42307009 X X N42250123 M 23AECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250124 M 23AECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250125 M 23A ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250126 M 23AECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250201 M 23B EGG N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250202 M 23B ECC N42307001 N42307002 N42307008 N4230700
23. 9 N42307007 N42307004 N42250207 M 23B ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250208 M 23B ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250209 M 23B ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250210 M 23B ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250217 M 23B ECC N42307001 N42307002 N42307008 N42307009 X X N42250218 M 23B ECC N42307001 N42307002 N42307008 N42307009 X X N42250219 M 23B ECC N42307001 N42307002 N42307008 N42307009 X X N42250220 M 23B ECC N42307001 N42307002 N42307008 N42307009 X X X42270001 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270002 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270003 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270004 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270005 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270006 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 42270007 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270008 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270011 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270012 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270013 EC
24. Bracket Complete R42252001 6 8 WAGO Assembly N42270401 Table 6 10 lists the parts of the WAGO assembly and Figure 6 7 shows the parts location Table 6 10 Parts List for N42270401 Item No Description_________ ASTS USA Part No Flat Washer 5 16 Stainless Steel Washer Lock 5 16 322 Inside Diameter Screw Hex Head Cap 5 16 18 x 2 Terminal Ring Tongue 5 16 6 6 12 SM 6263A Rev 3 November 2010 Parts List E e AnsaldoSTS IN Dy E CLAN POST 1 6 13 Figure 6 6 Terminal Assembly SM 6263A Rev 3 November 2010 d AnsaldoSTS QA Parts List Figure 6 7 WAGO Assembly SM 6263A Rev 3 November 2010 6 14 N SM 6263A Rev 3 November 2010 mm we 7 AnsaldoSTS Parts List 6 9 Sensor Use Table 6 11 lists the sensors that are used with each switch machine See Figure 3 1 for the sensor locations Table 6 11 Sensor and Switch Machine List MACHINE TYPE LOCK 1 LOCK 2 POINT 1 POINT 2 AUX 1 AUX 2 N42250001 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250002 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250003 M 3 ECC N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 N42250004 M 3 ECC N42307001 N42307002 N42307008 N423070
25. C Retro N42307001 N42307002 N42307008 N42307009 X X X42270014 ECC Retro N42307001 N42307002 N42307008 N42307009 X X X42270015 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270016 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270017 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 X42270018 ECC Retro N42307001 N42307002 N42307008 N42307009 N42307007 N42307004 6 16 SM 6263A Rev 3 November 2010 D c AnsaldoSTS RAIL Team and Technical Support 7 RAIL TEAM AND 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 product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam O ansaldo sts us SM 6263A Rev 3 November 2010 7 1 AN d RAIL Team and Technical Support AnsaldoSTS E Y AnsaldoSTS End of Manual 7 2 SM 6263A Rev 3 November 2010
26. C is opened and the MCU is disabled When this occurs the RED motor disabled LED illuminates on the ECC Motor power is now disabled while ECC power still remains for troubleshooting capability Both the normal and reverse indication outputs are shunted when not in use When the machine is fully locked and detected in the normal position for example the reverse indication output is shunted This is identical to using the shunt bar on existing M style circuit controllers A continuous wayside battery feed to the ECC is required to power the unit The ECC will operate over a range of 10 to 16 VDC however it is recommended that the unit has a minimum voltage level of 12 VDC measured between Terminals 17 and 20 on the WAGO terminal strip in the motor compartment refer to Step 5 of Section 4 4 1 3 2 ECC Diagnostic Information The ECC is equipped with a series of LEDs to indicate the current state of the switch machine Dual colored LEDs are provided to indicate the state of each vital point and lock sensor Green LEDs are provided for indication input indication output and auxiliary sensor state definition SM 6263A Rev 3 November 2010 3 3 E Functional Description AnsaldoSTS Red LEDs are provided to determine when the motor is disabled and when the ECC is in a latched out state Table 3 1 describes what the ECC diagnostics represent 3 2 1 Diagnostic Modes of Dual Colored LEDs The dual colored LEDs that represent the
27. M 6263A Rev 3 November 2010 77 AnsaldoSTS Installation 3 Remove the four 1 2 13 bolts A1 and lock washers securing the top bearing C One of these bolts will be 3 4 longer than the others ADJUSTING NUT R CLUTCH SPRING CLUTCH HOUSING GEAR FELT WASHER OIL SEAL FABRIC DISC CLUTCH PLATE Figure 4 4 Friction Clutch Assembly F P B Bl C2 C H SEE FIGURE 4 6 FOR LEGEND KAI Y AT MAG A y SR Y SS ARI S N Z LES SE Sil D SN EM oo LN Figure 4 5 Sectional View of M 23 Gearbox From Motor End Right Hand Assembly SM 6263A Rev 3 November 2010 4 13 N Installation d AnsaldoSTS 4 Remove the cotter pin at the top of the main crank Remove the 1 2 castle nut B1 and washer B2 from the top of the main crank and lift the top bearing C from the dowel pins being careful not to bend the bearing plate NOTE The rectangular key C1 may come out with the top bearing Check under the top bearing to see if the key has been removed and if so place the key in a safe spot for reinstallation 5 Remove the rectangular key C1 from the top bearing bushing C2 Remove the top bearing bushing the hand throw pinion D and the spacing collar E from the top end of the crank 6 Lift the hand throw lever to the vertical position and loosen the
28. M 6263A Rev 3 November 2010 4 3 ANN 7 AnsaldoSTS Installation 659 9L99 XXZC0ZB5VN dg NOLLONAP HOVA MS Saz d zo Z ds Kees ou HI SC w250 tc 10053 9dH1 318VSIO TIVANVA car sar Sdr JUDO P SS et Lar var zr SIE OLNV J5 d5 d5 d5 d5 d5 d5 d5 d5 db db d5 kas Noj 2Oouz OEZO EE Oo PO HO O Si 7 Z L 32901 L UN el xnv ua NE la ug NE er na m na ml na d na 3E UL v ssl COLE hee ee ae Z3026tA Figure 4 1 Jumper Locations on the Junction Board SM 6263A Rev 3 November 2010 4 4 SS 77 AnsaldoSTS Installation 4 3 Point Detector and Auxiliary Sensor Adjustment NOTE Auxiliary sensors are optional non vital sensors and are only supplied when required by the customer 4 3 1 Point Detector Sensor Gap The vital and auxiliary non vital point detector sensors Figure 4 2 must be located at a fixed dimension to optimize sensor response and performance The vital sensors are to be gapped to 0 075 from the face of the PD target and the auxiliary non vital sensors are to be gapped at 0 040 from the face of the target The tightness of the feeler gage between the head of the sensors and the target is not critical regarding the performance of the sensors Auxiliary Sensor Gap 0 040 Sensor Gap 0 075 Figure 4 2 Sensor Gap Definition Non Vital Senso
29. O FOR MACHINES WITH 360 1 BLACK WHITE T Ge 2 GEAR RATIO CONNECT WIRE 1 TO WAGO TERMINAL 29 amp 3 8 9 Greund Terminal WIRE 2 TO WAGO TERMINAL 30 BROWN WHITE z P 12 Point Sensor 2 o Green Bi Polar Normal A RED vn io Auxiliary Sensor 2 E c N42400801 JCT BOX W O SEALING PLUGS To 5 E BE USED WITH AUXILIARY SENSORS ORANGE raume WAGO Ground Stud Q To AAR Terminal 2 N42400802 JCT BOX W SEALING PLUGS TO 14 BE USED WITHOUT AUXILIARY SENSORS Lock Sensor 1 Lock Sensor 2 YELLOW WHITE T View A Proximity Sensor Layout amp Identification Earth Ground ZA INDICATED POLARITY DRIVES POINTS RIGHT SEE VIEW A NI REMOVE GROUND WIRE IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY JUNGTION BOX E N42400801 REFERENCE DRAWING F422152C R N42400802 Figure 4 13 Internal Wiring Diagram High Voltage Derail Machine SM 6263A Rev 3 November 2010 4 33 34 7 AnsaldoSTS Troubleshooting 5 TROUBLESHOOTING Table 5 1 is a troubleshooting matrix that covers ECC failure modes problems the possible cause s of the problem and the possible solutions to the problem To use the troubleshooting table identify the problem being experienced from the left hand problem category column The possible causes of the problem are listed in the center column and the possible solutions to the pro
30. RRITORY REFERENCE DRAWING F422152B Installation Figure 4 12 Internal Wiring Diagram Low Voltage Control Unit with Wound Field Motor SM 6263A Rev 3 November 2010 4 31 32 N e AnsaldoSTS Installation Auxiliary Sensor 2 Motor Cutout Contacts 49 and 50 WARN ING Maintenance Bi Polar Terminals 49 50 21 and 23 are Non Vital and should Point Slate o STT off o never be used to clear signals Sensor 1 D B l l 8 O O Lock Tape lead to harness OR only for 115V source Blue LI E LI o LI O for field applications G Lock with 115V source Violet reen Yellow ISI Motor Gontol Unit Reto Machine amine Sae e o JE O A N473039 01 high voltage 189 1 Brown 2 tio Lo Oo U gear ra Combine Black c NT 1 0 O 8 O Red Counter e to terminal 8 oma O LI o UB O 4 AAR Terminal Block Local LI O s Li O Local Request Red i E E 2 Lo o LI IG Ll O Normal Request To WAGO IN 3 FR gt Ground Stud a4 E Connnect lead SC o 3 O Rev
31. STS Table of Contents List of Figures Figure 1 1 Left Hand and Right Hand Switch Machines enne 1 4 Figure 2 1 ECC System Block Diagram sss ener entrent nennen snnt nennen en 2 2 Figure 3 1 View Standing at Controller End of Machine 3 2 Figure 4 1 Jumper Locations on the Junction Board nennen 4 4 Figure 4 2 Sensor Gap Definition ener nnnm 4 5 Figure 4 3 Initial Point Detector Bar Setup iret 4 7 Figure 4 4 Friction Clutch Assembly sessi rennen nnn 4 13 Figure 4 5 Sectional View of M 23 Gearbox From Motor End sse 4 13 Figure 4 6 Sectional View of Gearbox Looking from Motor End 4 15 Figure 4 7 Standard Lever Interlock Assemblies for M 23 Switch Machine 4 19 Figure 4 8 Sectional Views of M 23 Dual Control Mechanisme 4 24 Figure 4 9 Wiring Changes from 3 Wire and 5 Wire to 2 Wire Motor Control 4 25 Figure 4 10 Internal Wiring Diagram REENEN 4 27 Figure 4 11 Internal Wiring Diagram Low Voltage Control Unit with Permanent Magnet Motor 4 29 Figure 4 12 Internal Wiring Diagram Low Voltage Control Unit with Wound Field Motor 4 31 Figure 6 1 Circuit Controller ECC Aesembiy sse rennen 6 5 Figure 6 2 Circuit Controller CGompartment ementi ne 6 3 Figure 6 3 Junction Box Assembly lt 6 7 Figure 6 4 Point
32. Terminals 17 controller may or may not N12 and 20 B12 Ensure all wires on cables TB1 reset and TB2 are properly terminated on the WAGO terminal strip and that the cable plug connectors are properly secured to the ECC box Resistor may be in series Bypass the resistor so that the ECC gets the proper in with the battery supply line voltage voltage All diagnostic LEDs are A Cable TB2 is improperly 1 Ensure TB2 plug connector is properly secured and properly lit on the ECC a connected terminated locked to the ECC box Ensure all 10 color coded continuous vertical row of or is defective wires are properly terminated on the WAGO terminal GREEN LEDs is strip and that all crimped wire ferrules are properly observed yet no secured to the end of each wire Indication Output is B Defective ECC or 1 Remove cable TB1 and reconnect initiating an ECC present on WAGO improper software processor reset If the unit resets and the LEDs terminal strip no voltage execution by the ECC restore re check for presence of voltage output on is present between processor WAGO Terminals 1 and 3 entire unit and return to ASTS USA for analysis Sensors do not turn ON A Sensor not properly 1 Ensure proper termination of the brown and blue when target or lock box is connected to junction sensor wires to the corresponding terminals in the in front of more than 50 box Junction Box terminals are labeled on the PC board of the sensor face BR for brown
33. UTOUT CONTACT TERMINAL BOARD amp ere MOTOR CONTROL UNIT MCU HIGH POWER FET SWITCHES FIELD CABLE AND WAYSIDE L BATTERY FOR ECC MOTOR COMPARTMENT Figure 2 1 ECC System Block Diagram 2 2 SM 6263A Rev 3 November 2010 gt 7 AnsaldoSTS Functional Description 3 FUNCTIONAL DESCRIPTION 3 1 Functional Overview The ECC system is functionally equivalent to the ASTS USA N285638 circuit controller mechanism Being electronic it has no mechanical contacts or cam arrangements The motor control unit MCU emulates the motor cutout contacts from the mechanical controller in that it is continuously set up to move the machine to the opposite direction when in the full normal or reverse positions This MCU provides the same make before break motor control circuitry as in the existing M 3 M 23 controllers All proximity sensors used in the ECC system vital and auxiliary non vital are used under normally ON conditions In other words no logic condition of the ECC is dependent upon the point detection locking or auxiliary sensors being OFF to make a decision The only time the OFF state of the sensors is relevant is when determining the locked and detected position of the machine For example for the switch indication to be energized in the Normal position both the normal point and lock sensors must be ON and the reverse point and lock sensors must be OFF The vital point and lock sensors work in predetermined
34. aV 1000 Technology Drive Pittsburgh PA 15219 cw AnsaldoSTS 645 Russell Street Batesburg SC 29006 SM 6263A Electronic Circuit Controller ECC Upgrade Kit Installed in Existing M 3 and M 23 Style Switch Machines Copyright 2010 SM 6263A Rev 3 Ansaldo STS USA Inc November 2010 n e AnsaldoSTS Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible
35. ally connected to the DIN rail and serve as a means by which the 14 gas tube lightning arrestors make contact with the base of the machine No other wires should be terminated to these points Terminals 1 and 3 are for field connections to a two wire bipolar indication output circuit a Normal indication is defined as on Terminal 3 and on Terminal 1 b Reverse indication is defined as on Terminal 3 and on Terminal 1 c If there is no output Terminals 1 and 3 are shunted Terminals 4 6 7 and 9 are for field connections to a four wire indication output circuit a Normal indication is defined between Terminals 7 and 9 9 being positive and 7 being negative b Reverse indication is defined between Terminals 4 and 6 6 being positive and 4 being negative SM 6263A Rev 3 November 2010 E e AnsaldoSTS Installation c If there is no output on the paired terminals they are shunted CAUTION When connecting the ECC Indication Outputs to the drive switch correspondence relays ensure the relay controls are properly snubbed with a resistor to minimize the possible inductive kickback to the ECC when the field in the relay coil collapses Ensure that no external source is applied across any of the outputs 4 Terminals 10 12 13 and 15 are for indication input field connections from an adjacent machine s indication output circuit or can be jumpered in the application of a single machine
36. also serves as a terminal for the surge suppressor PCB used for lightning protection 4 Terminal 5 is the termination point for Terminal 51 from the hand throw contacts Terminal 6 is the termination point for the negative internal permanent magnet motor wire A gold nut test link is provided between these two terminals to disconnect motor power when performing maintenance on the machine SM 6263A Rev 3 November 2010 4 11 N Installation d AnsaldoSTS 5 Terminals 7 and 8 are designated for motor compartment heater wire termination 4 6 Sensor Identification and Termination in the Junction Box The vital point detector sensors are designated PS1 and PS2 The vital locking sensors are designated LS1 and LS2 The auxiliary point detector sensors are designated Aux1 and Aux2 It is important to note that PS1 and LS1 always work in combination together and PS2 and LS2 always work together as well Refer to Figure 3 1 The four vital and two optional auxiliary non vital sensors are all terminated inside the Junction Box Figure 4 1 located underneath the circuit controller frame All six sensor wires are brought into the junction box through a six way cable grip and their brown and blue wires are terminated in WAGO cage clamp connectors The PC board inside the Junction Box identifies which sensors connect to each terminal and the color designation of each sensor wire BR for brown and BU for blue If any of the four vital sensors are w
37. arest cotter hole and insert a cotter pin after operating the machine manually with the hand throw lever to be sure that the mechanism does not bind Flare the end of the cotter pin per usual installation practice Check the adjustment of the motor cutout push rod Contacts should open when the end of the selector lever has been raised approximately 6 from the horizontal motor position Readjust both yoke eccentric bushings as described in Section 4 8 4 then secure it by tightening bolt G firmly Check that the machine can be operated by power and also that it shifts to hand throw operation from both Normal and Reverse positions Check that all bolts are drawn down tightly on their lock washers and that all cotter pins are in place Replace the gearbox cover and secure it to the gearbox with the two 5 8 11 x 2 hex head bolts removed in Step 1 of Section 4 8 1 1 SM 6263A Rev 3 November 2010 uw AnsaldoSTS Installation LEVER INTERLOCK INTERLOCK ASSEMBLY ASSEMBLY STOP SCREW WHEN USED 0000 E 0000 oooo c reso o DIAGRAM A L H LAYOUT L H POINT NORMALLY CLOSED STOP SCREW WHEN USED DIAGRAM B R H LAYOUT R H POINT NORMALLY CLOSED LEVER INTERLOCK ASSEMBLY N NG
38. artment SM 6263A Rev 3 November 2010 6 3 RN Parts List d AnsaldoSTS 6 2 Circuit Controller ECC Assembly N422529 XX Table 6 3 lists the parts of the circuit controller ECC assembly and Figure 6 2 shows the parts location Table 6 3 Parts List for the Circuit Controller Assembly N422529 XX ltemNo Description ASTSUSAPartNo 1 Controller Frame M4237002 2 Lock Box Sensor Bracket M2370602 3 LockSensor LS1 Moj 4 LockWasher M18 J4751210138 Dowel Pin 3 8 x 3 47 8 ha Hegg ap HELE INN WasherS 8 Lock 19047779 o Washer 3 8 Lock J047779 Junction Box Assembly EE IE M 23 Upgrade with Plugs lama Not Used En Used NotUed CNA FE Spring Lock 5 16 J4751380112 Harness Clamp J703005 12 Point Detector Sensor Assembly with N42252401 Auxiliary Sensors Pin 1 x 0 250 dia M42371801 Sensor Bracket Insulator M42370301 15 Local Remote Switch Assembly M 23 Upgrade Screw Skt Cap 1 4 20 x 3 4 Screw Skt Head Cap 5 1618 x 1 When Used N42252801 6 4 SM 6263A Rev 3 November 2010 Parts List e AnsaldoSTS Figure 6 2 Circuit Controller ECC Assembly 6 5 SM 6263A Rev 3 November 2010 RN Parts List d AnsaldoSTS 6 3 Junction Box Assembly N42252701 Table 6 4 lists the parts of the junction box assembly and Figure 6 3 shows the parts location Table 6 4 Parts List for the Junction Box Assembly lte
39. based on RH or LH configuration 2 Move the point detector bar to the Normal position matching the machine in Step 1 SM 6263A Rev 3 November 2010 4 7 3 N Installation d AnsaldoSTS Starting with the sensor holding bracket outside the target area at the extreme position of the bracket mounting plate slide the sensor holding bracket toward the target until the LED for Point Detected Normal just turns green on the ECC This is the starting point for the Vital Sensor 18mm Slide the sensor holding bracket two more serrations into the target corresponding to the 1 8 point movement differential each serration is 1 16 on center and hand tighten to prevent movement Slide the auxiliary sensor toward the target until the LED for Auxiliary Point Detected just turns green After ensuring a gap of 0 040 between the target and sensor face secure the hardware for the sensor Tightness of the feeler gauge between the sensor head and the target is not critical For the Reserve position operating bar out based on RH or LH configuration repeat Steps 1 through 5 above This time look at the LED s that correspond to the Reverse Position on the ECC 4 4 Wiring and Motor Control 4 4 1 WAGO Terminal Strip Connections WAGO Terminal strip connections are as follows Figure 4 10 Figure 4 11 and Figure 4 12 illustrate the internal wiring diagram of the ECC system 1 4 8 Terminals 2 5 8 11 14 18 and 22 are intern
40. blem are in the right column of the table Table 5 1 ECC Troubleshooting Problem Cause Solution 1 Motor power is present A MCU wired incorrectly 1 Confirm proper connections of MCU wires 1 and 2 in from the wayside but WAGO Terminals 29 and 30 per the internal wiring motor does not run diagram shown in Figure 4 10 Figure 4 11 and Figure 4 12 wires on AAR terminal posts B Motor is DISABLED by 1 In M 23 with ECC ensure motor cutout proximity ECC Red Motor sensors in gearbox and on transmission box are Disabled LED is ON adjusted properly and both indicate ON by the illumination of the sensor s yellow LED 2 In an M 23 switch machine equipped with an ECC ensure two wires connecting motor cutout contact to WAGO terminal strip are connected properly and that the 750 ohm resistor is properly installed between WAGO Terminals 33 and 34 C Gold Nut circuit link on Ensure that the Gold Nut connection is closed and AAR terminal posts is properly secured with an AAR jam nut open 2 Motor runs but not in Incorrect motor polarity Reverse motor wires on motor terminals not on AAR proper direction causing terminal posts friction clutch to slip 3 Asingle dual colored A Corresponding sensor 1 Ensure proper termination of the brown and blue LED is flashing RED wire is shorted open or sensor wires to the corresponding spring terminals in not properly connected the Junction Box terminals are labeled on the PC
41. board BR for brown and BL for blue B Sensor is adjusted 1 For point detection sensors adjust the linear sensor marginally between ON location away from the ON OFF threshold as and OFF with respect described in the Initial Setup section of the to it s target corresponding product service manual 2 For locking sensors ensure that the machine is in the fully locked position and the machine has completed its stroke Note linear position of the locking sensors is not adjustable 1 Ensure that the configuration jumper is installed in RED jumper latch out jumper slots in Junction Box 5 All four dual colored A Incorrect configuration 1 Ensure that one jumper is installed in the latch out LEDs are flashing RED jumper installation in jumper slots and one jumper is installed in the junction box LHPC RHPC jumper slots The ECC will not work if either jumper is absent or if multiple jumpers are installed in any one configuration SM 6263A Rev 3 November 2010 5 1 EN gt Troubleshooting 7 AnsaldoSTS Problem Cause Soluton B Junction box cable JB1 1 Ensure JB1 cable keys are aligned properly the is not properly connector is fully inserted and the locking ring is connected to ECC box turned clockwise until it locks in place 6 All LEDs on the ECC A Insufficient low battery Ensure a continuous battery feed of at least 10 VDC with drop out and the feed level to the ECC proper polarity is present on WAGO
42. combination point detector bar and target that accurately reports the true displacement of the switch points The serrated linear slide assemblies provide simple and dependable proximity sensor adjustment with respect to the target The ECC provides advanced diagnostics for identifying the current state of the machine and the indication state of an adjacent daisy chained machine LEDs on the ECC indicate the delivery of indication power and auxiliary indication power to the wayside as well as provide information on motor power availability and the state of the latch out function SM 6263A Rev 3 November 2010 1 1 Introduction Ny d AnsaldoSTS To avoid severe personal injury open the gold nut test link in the motor compartment prior to performing any internal machine maintenance Always keep hands and feet clear of switch points and the internal moving parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine 1 3 Purpose of Manual This service manual provides descriptive information specifications and installation and maintenance procedures for the ASTS USA Electronic Circuit Controller which is installed on the M 3 and M 23 Switch Machines 1 4 Abbreviations Acronyms and Definitions ac AAR AREA AREMA AWG CAUTION dc ECC Front of Machine FRA Latch Out alternating current Association of American Railroads Communication and Signal S
43. e is converted from right to left hand operation the RHPC LHPC jumper has to be inserted in the proper location on the junction board in the Junction Box Refer to Section 4 1 3 for this procedure 4 22 SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation 4 9 Final Inspection and Testing after Installation To avoid severe personal injury open the gold nut test link in the motor compartment prior to performing any internal machine maintenance Always keep hands and feet clear of switch points and the internal moving parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine Ensure that all switch connecting rods are square to the switch point prior to fastening the switch mechanism to the ties 2 Ensure that all rods operate without binding and properly clear the base of the stock rail 3 Nothing is gained by excessive point pressure Adjust the switch adjust basket until the switch points just close in either position 4 Ensure the switch machine is installed per the applicable installation drawings and that all fasteners are properly secured 5 Final adjustment of the lock rods and point detector system should be performed in accordance with standard railroad operating practices AREMA recommended practices and FRA Rules and Regulations 6 Independent breakdown testing of the switch machine circuitry should be performed in accordance with standard ra
44. ection currently known as AREMA American Railway Engineering Association American Railway and Maintenance of Way Association formerly known as AAR American wire gauge Caution statements indicate conditions that could cause damage to equipment direct current Electronic Circuit Controller The physical area of the switch machine closest to the motor Federal Railroad Administration A device that does not allow switch point indication to restore if the switch point moves away from the stock rail point detection is momentarily lost This function will be activated if the point sensors are actuated before their corresponding locking sensors are actuated SM 6263A Rev 3 November 2010 n Left Hand Switch LHPC PD Point Detection Locking MCU MOV Non Vital Circuit PCB Rear of Machine Reference Designator Right Hand Switch gt 7 AnsaldoSTS Introduction Latch Out The term latch out restoration refers to resetting the machine to an operable Restoration switch machine indication state from a latched out condition LED Light emitting diode The position of a switch machine designated when the machine is located on the left hand side of the track looking into the switch points in the direction of the arrow as shown in Figure 1 1 Left hand point closed which refers to the switch point position when the point is normally closed to the left hand side looking into the switch points in the directio
45. erse Request TE g Ee Do El o Maintenance Bi Polar Normal Maior Cutout Machine Sch al 0 Ground Terminal 53 Green n L O Maintenance Bi Polar Normal 39 4 lo I El m L O Battery Input B12 ac E Ez ET UR S D az 5 UR o Ground Terminal Eb ol TU Battery Input N12 l 29 p E N47303401 N m O e 2 ac Ex By aie s H 2 Mi Ni Normal Input zd Se I 29 8 3208 Q SH LI O Ground Terminal 2 22 gt o 2 S HET Brown o e Q Normal Input BLACK 5593 3 el Z Slate 1 2868 e L O Reverse Input o o RT BROWN 2 oo M N E FE o Ground Terminal RED 3 33 al sf Violet U e Y o Reverse Input ORANGE g Sy s gt 58 Yellow 4 2350345 ZE e Ni O Normal Output Segond Qs YELLOW 5 se 3 3 98 sl Ground Terminal y E A i GREEN 6 E ER 5 Se e LI Ll O Normal Output 7 Permanent Magnet Motor Configuration BLUE 2 H ue FID 7 z ET e O Reverse Output E 8 Se 7 IE o Ground Terminal GRAV Ws O TA Dol ES 1 ASSEMBLE AND TEST PER EU 8557 ES Lk everse Output WHITE E gt Red Bi Polar N CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE Auxiliary Sensor 1 z O Bi Polar Normal CORRECT WITH 189 1 GEAR RATI
46. he motor control unit MCU houses the high powered FET electronic motor control circuitry The FET circuitry turns OFF motor power at the end of each stroke only after the machine is fully locked This feature eliminates the need for a large motor with high armature inertia to complete the machine s stroke in adverse weather conditions The local remote request switches are used to locally operate the machine similar to a wayside local control panel One toggle switch is used to take local or remote control and the other toggle switch is used to cycle the machine from normal to reverse and vise versa SM 6263A Rev 3 November 2010 2 1 D a Functional Description 7 AnsaldoSTS The cycle counter tallies each complete cycle of the switch machine i e the counter increments each time the machine completes a cycle from normal to reverse and back to normal again The counter cannot be reset so the operational history of the machine is preserved CIRCUIT CONTROLLER COMPARTMENT mmm mmm mmm mmm ECC BOX MICROPROCESSOR amp POWER SUPPLY DIAGNOSTIC LED DISPLAY LATCH OUT RESTORATION PUSHBUTTON SENSOA TERMINALS LHPC RHPC amp LATCH OUT OPTION JUMPER CONFIGURATIONS P P L L s s S S 1 2 1 2 VITAL POINT VITALLOCKING AUXILIARY POINT LOCAL REMOTE SENSORS SENSORS SENSORS JUNCTION BOX xc gt MXC REQUEST SWITCHES CYCLE COUNTER EXISTING MOTOR C
47. hine to the opposite position and back 2 If the latched out condition restores the pushbutton is defective replace the ECC unit at your earliest convenience and return to ASTS USA for repair 3 If the latched out condition does not restore and all vital sensors are properly functioning replace the ECC unit and return to ASTS USA for repair SM 6263A Rev 3 November 2010 5 3 A Troubleshooting 7 AnsaldoSTS AV Y AnsaldoSTS 5 4 SM 6263A Rev 3 November 2010 e AnsaldoSTS Parts List 6 PARTSLIST Table 6 1 Various Available ECC Configurations Part Number N42252901 M 23 M 3 w ECC without Auxiliary Sensors N42252902 M 23 M 3 w ECC with Auxiliary Sensors N42252903 M 23 M 3 w ECC without Auxiliary Sensors without Local Remote Switch M 23 M 3 w ECC with Auxiliary Sensors MESEN without Local Remote Switch SM 6263A Rev 3 November 2010 6 1 RN Parts List d AnsaldoSTS 6 1 Circuit Controller Compartment Table 6 2 list the parts of the circuit controller compartment and Figure 6 1 shows the parts location Table 6 2 Parts List for the Circuit Controller Compartment 5 Screw 1 4 20 x 24 Skt Cap Set Screw 1 2 20 x 1 2 Cup Point 90 HRNSS M 23 Upgrade SM 4 key TB2 N42215104 6 2 SM 6263A Rev 3 November 2010 e AnsaldoSTS Parts List E422698 A Figure 6 1 Circuit Controller Comp
48. ht hand side of the track looking into the switch points in the direction of the arrow shown in Figure 1 1 root mean square method for expressing ac voltage rating A vital determination of a safe switch configuration due to positive indication that the switch machine has properly thrown locked and detected switch point closure A device which performs the three operations of unlocking operating and locking a switch movable point frog or derail Any circuit with a function that affects the safety of train operation Registered trademark for WAGO Corporation Warning statements indicate conditions that could cause physical harm serious injury or loss of life LEFT HAND 1 RIGHT HAND 1 Figure 1 1 Left Hand and Right Hand Switch Machines 1 5 Safety Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to the 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 SM 6263A Rev 3 November 2010 AnsaldoSTS Equipment Description 2 EQUIPMENT DESCRIPTION Please refer to Figure 2 1 for a block diagram of the ECC System 2 1 Junction Box The ECC box is connected to the junction box via cable JB1 The junction box is the junction point where the four vital sensors two for point detec
49. ilroad operating practices AREMA recommended practices and FRA Rules and Regulations 7 Tf the machine is equipped with a local remote feature ensure the local remote toggle switch is in the Remote position prior to leaving the installation site 8 Ensure all covers are properly installed and locked prior to leaving the installation site SM 6263A Rev 3 November 2010 4 23 Ny Installation 4 AnsaldoSTS CLUTCH FOR HAND OPERATION ROLLER SELECTOR CLUTCH SPRING SELECTOR LEVER SHAFT UPPER SPRING CUR SELECTOR CLUTCH YOKE LOWER SPRING CUP WORM GEAR CLUTCH FOR MOTOR OPERATION LOWER ROLLER NOTE SELECTOR CLUTCH ASSEMBLY COMPRISES PARTS MARKED BEARING CUP UPPER SPRING CUP HAND THROW BEVEL GEAR HAND THROW LEVER SHAFT HAND THROW PINION wii Wo ESTA 2 ABD YE SELECTOR v A LN CLUTCH FOR HAND OPERATION me i AU IF ECCENTRIC BUSHING SN v AE aA gt gt YN SELECTOR CLUTCH YOKE SELECTOR CLUTCH SPRING CLUTCH FOR MOTOR OPERATION LOWER SPRING E E WORM GEAR MAIN CRANK SHAFT Figure 4 8 Sectional Views of M 23 Dual Control Mechanism Ges ZZ vy ft un d X 4 24 SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation 7 Connect Together 3 Wire PM Motor for 2 wire control FROM M23 with ECC Retrofit N24 R d Polarity Con
50. ired incorrectly the corresponding LEDs on the ECC will be Flashing Red If the auxiliary sensors are wired incorrectly they simply will not operate There is a yellow LED on the back end of each auxiliary sensor to determine if it is operating properly 4 7 3 and 5 Wire Conversion to 2 Wire Control Figure 4 9 illustrates a typical 3 and 5 wire relay control scheme converted to the recommended 2 wire control system Conversion from a 5 to 2 wire configuration is best suited for changes in the wayside house or bungalow A 3 to 2 wire conversion can be performed at the wayside location or in the machine by connecting two of the three wires together as shown 4 8 Right Hand to Left Hand Conversion and Vice Versa 4 8 1 Conversion of Gearbox NOTE Although this procedure can be done in the field ASTS USA recommends this procedure be done in the shop 4 8 1 1 Dismantling Refer to Figure 4 4 Figure 4 5 and Figure 4 6 1 Remove the two 5 8 11 x 2 hex head bolts securing the gearbox cover to the gearbox and lift the cover retain the cover to use as a receptacle for the parts which will be removed in future steps 2 Place the hand throw lever in the Normal position and the selector lever in the Motor position The machine must be in its full stroke position Insert a 1 2 drive into the adjusting nut on the friction clutch assembly R and turn it to drive the mechanism to its complete full stop Figure 4 4 4 12 S
51. mNo Description ASTSUSA Part No 6 Locknut PG 21 32 mm wide 37002160011 8 SealRing Altech PG13 5 PE _ J7002160013 9 Locknut Nickel Plated Brass J7002160006 NotUsed The wiring chart for connecting the wiring harness Item 11 to the PCB Item 2 is given in Table 6 5 Table 6 5 Wiring Chart for the Junction Box Assembly Harness 6 6 SM 6263A Rev 3 November 2010 Parts List e AnsaldoSTS V IIVL3d Figure 6 3 Junction Box Assembly 6 7 SM 6263A Rev 3 November 2010 RN Parts List d AnsaldoSTS 6 4 Point Detector Sensor Assembly Without Auxiliary Sensors N42252401 Table 6 6 lists the parts of the point detector assembly without auxiliary sensors and Figure 6 4 shows the parts location Table 6 6 Parts List for N42252401 ASTS USA Part Description No 3 NotUsd pf MA 6 8 TerminalPost M130593 9 NotUsd pf 11 j NetUsed P 6 5 Point Detector Sensor Assembly With Auxiliary Sensors N42252402 Table 6 7 lists the parts of the point detector assembly with auxiliary sensors and Figure 6 4 shows the parts location Table 6 7 Parts List for N42252402
52. n of the arrow as shown in Figure 1 1 Point detector or point detection as in PD bar The positive indication achieved when the switch points are closed adequately against the stock rail Locking is achieved when the lock box connected to the slide bar enters the narrow locking notch of the lock rods and extends a minimum of 1 2 into the locking rod Motor control unit a high current solid state device used to control motor power Metal oxide varistor protection device for electronic components Any circuit with a function that does not affect the safety of train operation Printed circuit board The physical area of the switch machine furthest from the motor An abbreviation assigned to designate an electrical component It generally consists of a capital letter and a number Each letter designates a particular type of component For example L identifies an inductor and R identifies a resistor The position of a switch machine designated when the machine is located on the right hand side of the track looking into the switch points in the direction of the arrow shown in Figure 1 1 SM 6263A Rev 3 November 2010 1 3 Introduction RHPC rms Switch Machine Indication Switch and Lock Movement and or Mainline Switch Machine Vital Circuit WAGO WARNING Sy d AnsaldoSTS Right hand point closed which refers to the switch point position when the point is normally closed to the rig
53. o as not to cause intermittent indication failures under shock and vibration conditions The sensitivity of the vital sensors can be adjusted in 1 16 increments to accommodate for excessive lost motion in the external point detection connections Tighten the AAR hardware to properly secure the sensor bracket Place a 1 4 obstruction in the switch point 6 back from tip of point It may be necessary at this time to float the lock rods to allow the switch machine s slide bar to travel full stroke to properly check the point detection settings This is accomplished by loosening the hardware on the lock rod assembly and moving the lock rods so that the lock dog of the machine can enter the narrow notch With the obstruction placed in the switch point the corresponding normal or reverse point detected LED should be RED If not repeat the serrated bracket adjustment procedure Steps 1 through 4 moving the bracket only two serrations into the target instead of three SM 6263A Rev 3 November 2010 A 7 AnsaldoSTS Installation Figure 4 3 Initial Point Detector Bar Setup 9 If the machine has been equipped with the optional auxiliary sensors their position is fixed and no adjustment is required 4 3 3 Auxiliary Sensor Non Vital NOTE Auxiliary sensors are optional non vital sensors and are only supplied when required by the customer 1 Place the switch machine in the Normal position operating bar
54. obe tetera Local o U El J o Local Request et to o O s J o Normal Request 3 lo O El 0 Reverse Request GT o R TT O Maintenance Bi Polar Normal eT s o Ground Terminal Green Ni O s lt Maintenance Bi Polar Normal 4 O o L El em O Battery Input B12 Black Ems eT E o Ground Terminal o El amm O Battery Input N12 Yellow Ll O o Normal Input Sp E O Ground Termina Brown Ni EDO Q Normal Input Slate o I El O Reverse Input U al E TGI ol Ground Terminal U eL Bl L e L o Reverse Input IW O TT Normal Output ce s o Ground Terminal en O A O Normal Output ue Pl EFE 9 Reverse Output SH e L 9 Ground Termina Nun O eL E o Reverse Output Red a sf o LI O Bi Polar Normal ct Y O Ground Terminal Green Nl O E SE 0 Bi Polar Normal WAGO Ground Stud To AAR Terminal 2 Earth Ground Motor Control Unit Retrofit Machine Motor Cutout Contacts Permanent Magnet Motor Configuration Gold Nut Heater gt Terminals N473039 01 high voltage 189 1 gear ratio AAR Terminal Block To WAGO Ground Stud 1 ASSEMBLE AND TEST PER EU 8557 CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE CORRECT WITH 189 1 GEAR RATIO FOR MACHINES WITH 36
55. of the machine both ON MOTOR FRONT and ON MOTOR REAR are relative to GND When lock sensor LS2 turns ON the ON MOTOR FRONT line switches to GND In response the motor controller opens the motor to the polarity of current that would continue motion in the same direction Additionally the counter is energized momentarily and one count is registered Operation in the opposite direction is the same with ON MOTOR REAR switching to stop the motor however the counter does not respond Terminals 32 through 34 are the termination points for the motor cutout circuits In an M 23 upgraded with an ECC the existing motor cutout contact in the circuit controller compartment is to be connected to Terminals 32 and 33 An 750 ohm resistor is series connected in the circuit to disable motor power when the selector lever is actuated for hand throw operation 4 5 AREMA Terminal Post Connections There are eight 8 AREMA binding post terminals labeled 1 through 8 accordingly 1 Terminal 1 is the termination point for the red MCU control wire one of the two field motor control wires It also serves as a terminal for the surge suppressor PCB used for lightning protection 2 Terminals 2 and 3 are common terminals used for grounding purposes They are also terminals for the surge suppressor PCBs connected to Terminals 1 and 4 3 Terminal 4 is the termination point for the second field motor control wire and for Terminal 52 from the hand throw contacts It
56. of the two auxiliary sensors mounted on the linear slides above the two vital point detector sensors The auxiliary sensors offset from the vital sensor by a 1 8 sensing range differential This means that if the vital sensor is adjusted to detect a 1 4 linear displacement of the point detector bar 1 e turn OFF the auxiliary sensor will turn OFF after the bar has displaced only 1 8 Similarly 1f the vital sensor is adjusted to sense 3 8 point detector rod movement the auxiliary sensor will turn OFF after the bar has moved 1 4 This 1 8 differential provides the ability to predict a switch failure caused by sand or ice building up in the switch points or switch point movement resulting from extreme temperature changes etc The auxiliary sensors indicate that while the machine is still within the FRA guidelines for maintaining switches the machine is on the verge of being obstructed A normally energized bipolar output is provided on the WAGO terminal strip to be utilized on the wayside to notify operators or maintenance personnel that a problem is developing The mechanical motor cutout contact in the existing M style machine is still utilized to both remove motor power and de energize indication circuits when opened The existing contact arrangement is terminated on the WAGO terminal strip in the motor compartment and is placed in series with an 750 ohm resistor When the contact is opened the series resistive circuit to the EC
57. olored LEDs uit 3 4 4 INSTALLATION a A 4 1 4 1 Junction Box Jumper Configuration ssssssssesesesseeeeeeenene eterne nnne nnns 4 1 4 1 1 RHPO EHPC Jumpers 5 12 dal Tla ode inke ENEE 4 1 4 1 2 EatchsQut J mbp elrs 4 nerit e tte t eto eee ea e at eit ve Ent 4 1 4 1 3 Changing the Jumper Configuration essere 4 1 4 2 ECC Power and Indication Input Gen 4 2 4 2 1 Single Machine Setup enne entree nennen sinn intret rene 4 2 4 2 2 Multiple Machine Gen 4 3 4 3 Point Detector and Auxiliary Sensor Adjustment s sse 4 5 4 3 1 Point Detector Sensor Gap 4 5 4 3 2 Point Detector Sensor Adjustment sse 4 6 4 3 2 1 Initial Set UD ER 4 6 4 3 3 Auxiliary Sensor Non Vital enne nnne nen 4 7 4 4 Wiring and Motor Control 4 8 4 4 1 WAGO Terminal Strip Connections sse nennen 4 8 4 4 2 Motor Control ion c tite te EE tide s 4 11 4 5 AREMA Terminal Post Connections nennen nnne nennen 4 11 4 6 Sensor Identification and Termination in the Junction Bos 4 12 4 7 3 and 5 Wire Conversion to 2 Wire Control 4 12 4 8 Right Hand to Left Hand Conversion and Vice Versa 4 12 4 8 1 Conversion of Gearbox uuu 4 12 4 8 1 1 Dismantling Refer to Figure 4 4 Figure 4 5 and Figure 4 6 4 12
58. om the shaft It may be necessary to lift on the yoke N to free the eccentric pin P on the selector shaft Remove the two 1 2 13 x 1 1 2 bolts A4 and washers that secure the lever shaft bearing M to the gearbox Grasp the hand throw bevel gear and remove the shaft assembly from the gearbox case The shaft will pull free of the bevel gear as it is pulled from the gearbox case Be sure that the bevel gear does not fall into the case as the shaft is removed NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused 4 8 2 2 Reassembly l 4 20 The lever assembly is to be installed on the opposite side of the gearbox case after the yoke support has been removed Place the bevel gear inside the gearbox case on the side where the lever shaft will be installed Insert the lever shaft into the opening on the gearbox case As the shaft enters the case position the bevel gear so that the shaft slides through the center of the bevel gear and that the keyways match It may be necessary to lift the yoke a bit to facilitate the eccentric pin P on the lever shaft assembly entering the slot on the end of the yoke SM 6263A Rev 3 November 2010 n e AnsaldoSTS Installation 4 8 3 NOTE A paper gasket is located between the lever shaft
59. on of the eccentric bushings NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused Secure the yoke to the yoke support using the 1 2 13 x 6 bolt G 1 2 nut and two lock washers removed in Step 10 of Section 4 8 1 1 Insert the lever assembly into the hub on the opposite side of the gearbox As the shaft enters the gearbox position the hand throw bevel gear F so that the gear slides onto the keyed shaft Position eccentric pin P on the selector shaft of the lever assembly so that it enters the slot on the end of the yoke Ensure the gear is firmly against its seat on the shaft SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation CAUTION Insertion of the lever assembly requires two persons to perform the procedure one to insert the lever assembly and one hold and guide the hand throw bevel gear onto the lever assembly shaft 5 With the hand throw lever vertical and the bevel gear firmly seated against the lever shaft tighten the set screw F1 in the hand throw bevel gear F 6 Secure the lever shaft bearing M to the gearbox with the two 1 2 13 x 1 1 2 bolts A4 and washers removed in Step 7 of Section 4 8 1 1 7 In order that the motor position of the selector lever will be toward the motor end of
60. ove the operating bar lug and place it on the operating bar on the other side of the switch machine Secure the operating bar lug with the cotter pin the 7 8 nut washer and 7 8 9 hex head bolt removed in Step 2 Install the operating bar covers on the sides of the switch machine One of the covers is designed to fit over the operating bar lug and can only be installed over the lug Secure the covers with the 1 2 bolts and washers removed in Step 1 SM 6263A Rev 3 November 2010 4 21 Ny Installation d AnsaldoSTS 4 8 4 Selector Clutch Adjustment Selector clutch adjustment should be checked annually When the selector lever is in the Motor position and the selector clutch teeth are in full engagement with the teeth on top of the worm gear so the motor drives the crank the top rollers on the operating yoke should be just clear of the upper spring cup This relation can be varied by adjusting the eccentric bushings G1 As shown in Figure 4 5 and Figure 4 6 the selector clutch yoke has one end supported on and driven by the finger on the selector lever shaft and its other end pivots on the eccentric bushings that are fixed by G When this bolt is loosened the eccentric bushings may be rotated to raise or lower the center line for the pivot holes in the yoke arms affecting the elevation of the yoke rollers The eccentric bushings have hexagonal heads one flat is stenciled N and the flats on either side of the N flat a
61. r Shown is Optional SM 6263A Rev 3 November 2010 4 5 AY Installation d AnsaldoSTS 4 3 2 Point Detector Sensor Adjustment The vital point detector sensors Figure 4 3 are mounted on serrated adjusting brackets which can be adjusted in 1 16 linear increments 4 3 2 1 Initial Set Up Adjust the point detector bar so that the PD target is centered or equally balanced in the machine see Figure 4 3 when the points are in the mid stroke position The point detector bar should travel equidistant from the center of the controller compartment when the switch travels from one extreme position to the other 1 Move the switch machine to one extreme position N or R it is not critical and ensure that the switch point is closed and up against the stock rail Loosen the PD bracket AAR nuts Lift the serrated bracket and slide the sensor toward the PD target keeping the bracket elevated so as not to engage the serrations Move the sensor to the target s edge until the corresponding Point Detected LED just turns Green on the ECC box Lower the serrated bracket to determine the ON OFF threshold location in the serrations Lift and move the sensor bracket three 3 additional serration positions 3 16 toward the center of the machine to assure that the sensor is not adjusted right on the ON OFF threshold This will ensure that a 1 4 point obstructed will be detected however the points will be allowed some movement up to 3 16 s
62. r Terminals A 21 and 23 are Non Vital and should never be used to clear signals Lock Sensor1 Lock Sensor 2 WAGO Ground Stud To AAR Terminal 45 Earth Ground Motor Control Unit Retrofit Hd Machine N473039 02 low voltage 360 1 and or 528 1 N473039 06 low voltage gear ratios AAR Terminal Block Motor Cutout Contacts Machine 4 Right Frame To WAGO Ground Stud Terminals Wound Field Motor Configuration 1 ASSEMBLE AND TEST PER EU 8557 CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE CORRECT WITH 189 1 GEAR RATIOS CONNECT WIRE 1 TO WAGO TERMINAL 29 amp WIRE 2 TO WAGO TERMINAL 30 FOR 360 1 amp 528 1 GEAR RATIO A N42400801 JCT BOX W O SEALING PLUGS TO BE USED WITH AUXILIARY SENSORS N42400802 JCT BOX W SEALING PLUGS TO BE USED WITHOUT AUXILIARY SENSORS A INDICATED POLARITY DRIVES POINTS RIGHT SEE VIEW A FOR MOTOR CONTROL UNIT SUFFIX 06 CONNECT WIRES 5 amp 6 TO WAGO TERMINALS 32 AND 34 AS SHOWN CONNECTIONS PROVIDE ACCESS TO RELAY INDICATION CONTACT INSIDE MCU REMOVE GROUND WIRE IF MACHINE IS INSTALLED IN ELECTRIFIED TERRITORY CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN ELECTRIFIED TE
63. r position 1 e toward the motor end of the machine and check to make sure that it moves the yoke N down 9 Interchange the Motor and Hand nameplates on the selector lever to correspond with the new lever positions SM 6263A Rev 3 November 2010 4 17 AY Installation d AnsaldoSTS 10 11 12 13 14 15 16 17 18 19 4 18 With the hand throw lever vertical place the collar E with the chamfer down on top of the main crank end Install the hand throw bevel pinion D engaging the tooth marked R for right hand assembly or L for left hand assembly with the punched marked master tooth space in the center of the hand thrown bevel gear F Carefully place the hand throw lever in the Normal position Be sure that the hand throw bevel pinion D remains in the proper position relative to the hand thrown bevel gear F With the selector lever in the Motor position rotate the friction clutch housing so that the motor clutch teeth are fully engaged Place the top bearing assembly C on the gearbox using the dowel pins as guides and secure it with the four 1 2 13 hex head bolts A1 and lock washers removed in Step 3 of Section 4 8 1 1 The motor cutout push rod should be held back to clear the adjusting rod until bearing is down Install the top bearing bushing C2 rectangular key C1 washer B2 on the top of the main crank Tighten castle nut B1 firmly then back it off to the ne
64. re marked and The N will be on top when the eccentric bearing is in its mean position When the eccentric bushings are turned to bring the mark up the yoke and its rollers will lift Alternately when the mark is up the yoke and its rollers are lowered To avoid twisting the yoke these marks should be kept turned to a like degree or Tightening bolt G holds the adjustment of the eccentric bearings When it is necessary to adjust the eccentric bushings check that the top rollers are free from the bearing on the upper spring cup while the selector clutch is fully down and in addition check that the rollers are not too high as follows 1 Place the selector lever in the Motor position when the worm gear is not in position to receive the selector clutch so that the teeth of Clutch for Motor Operation Figure 4 8 ride on top of the corresponding teeth of the worm gear 2 Insert a 1 8 length of a 14 soft copper wire between the opposed teeth The eccentric bushings should be adjusted the same degree or so that with the bolt tight the force between the opposed teeth will crush the wire to not more than 1 32 thick when the selector lever is thrown to the horizontal position for motor operation 3 Check that the upper rollers are free to turn when the selector clutch is fully engaged with the worm gear 4 8 5 Jumper Configuration Changeover When the switch machin
65. resistor value between WAGO terminals 33 and 34 from 820 to 750 on Figures 4 10 4 11 and 4 12 November 2010 Incorporated ECO 139712 391 and ECO 139712 392 revised Figure 4 10 Figure 4 11 Figure 4 12 and Figure 4 13 Incorporated ECO EM 2339 revised Table 6 3 Figure 6 2 Table 6 6 Figure 6 4 Table 6 8 Figure 6 5 Added Table 6 7 Table 6 8 Table 6 9 Figure 6 6 Table 6 10 Figure 6 7 and Table 6 11 Copyright 2010 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA USA 15219 3120 645 Russell Street Batesburg SC 29006 www ansaldo sts com All rights reserved ii SM 6263A Rev 3 November 2010 AnsaldoSTS Table of Contents Table of Contents As INTRODUCTION EE 1 1 0 0 PS 1 1 12 eelere TEE 1 1 1 2 1 ASTS USA Electronic Circuit Controller rra 1 1 1 3 Purpose of Manual t E en ceo Y e EE Here EY HE DRE RES 1 2 1 4 Abbreviations Acronyms and Definitions esssssssssseeeeneeeneen enne 1 2 1 5 Sa 1 4 2 EQUIPMENT DESGRIPTION EK 2 1 Zn A Uinc cm 2 1 2 2 WAGO TermimalSDEM meatus 2 1 2 3 Motor OL 0 01 01 La 101 LE 2 1 3 FUNCTIONAL DESCRIPTION EER 3 1 3 1 Functional Overvlew cnn crm 3 1 331 1 LateREOUELSOS UG eee c gr I Eee re Doa 3 1 3 1 1 1 Manual Restoration MN RE Gir 3 2 3 1 1 2 Automatic Restoration esna a E cnn n nano nc nr narrar naar rca 3 3 3 2 EGG Diagnostic Information cente oe tede deeper tec s pede e read 3 3 3 2 1 Diagnostic Modes of Dual C
66. s The ECC is designed to fit into both the M 3 and M 23 A or B style switch machines with permanent magnet motors The ECC uses four vital proximity sensors two to detect the position of the switch points normal or reverse and two to detect that the machine is fully locked normal or reverse The ECC is a microprocessor based controller that vitally monitors the state of the four vital proximity sensors and can identify each possible sensor state on off shorted or open In addition to the four vital proximity sensors the ECC can be equipped with an optional auxiliary point detection system This system provides a normally ON bipolar output to warn maintenance personnel of marginal switch machine operation The sensing threshold of each auxiliary sensor is offset from the vital point detector sensors by approximately 1 8 to detect switch point displacement before the vital sensors indicate point detector bar movement With the auxiliary system switch point displacement that is caused by debris build up or expansion and contraction of the rail can be detected before a switch failure occurs The M 23 with ECC proximity sensor system is a true linear detection device with no moving parts to wear The system requires no adjustment of the point detector bar but provides internal adjustment capability of the proximity sensors with respect to the point detector bar with the use of serrated linear slides The point detection system provides a
67. states of the vital point and lock sensors have three possible diagnostic modes red or flashing red as illustrated in Table 3 1 Green simply means the sensor is ON and is detecting its specified target Red means the sensor 1s OFF and not sensing the target Flashing red indicates an indeterminate state 1 e not ON or OFF In order to definitively distinguish between an ON and an OFF sensor state an indeterminate operating window is used between the two states As the target approaches the sensor the sensor will change from the OFF state to an indeterminate state and then to the ON state The LED will represent this by changing from red to flashing red and then to green The ECC will also produce a flashing red LED 1f the vital sensors are shorted open or wired incorrectly During normal switch operation the flashing red transition through the indeterminate state will not be noticeable The green LEDs for indication input and indication output are powered from the actual working voltages in the machine and not energized based on the microprocessor interpretation of the machine state The indication input LEDs are powered by the voltage present on WAGO Terminals 13 and 15 for normal and 10 and 12 for reverse The indication output LEDs are powered by the ECC power supply delivering the 12 volt indication output potential to the terminals on the WAGO strip Terminals 1and 3 for bipolar and Terminals 4 6 7 and 9 for four wire indication circuits
68. tch out LED on the ECC The latch out can be restored either manually or automatically SM 6263A Rev 3 November 2010 3 1 e Functional Description AnsaldoSTS i ae as rant uen i Figure 3 1 View Standing at Controller End of Machine with ECC Box Removed Aux Sensors Shown Are Optional 3 1 1 1 Manual Restoration NOTE In the manual restoration mode the latch out cannot be restored in either the hand throw or power mode of operation Maintenance personnel must depress the latch out restoration pushbutton to restore a latched out condition The latch out can be restored manually by pressing the momentary latch out restoration pushbutton on the ECC for one second and releasing this can be done in either the manual or automatic restoration modes but will only occur if the point and lock sensors are properly indicating 3 2 SM 6263A Rev 3 November 2010 gt 7 AnsaldoSTS Functional Description 3 1 1 2 Automatic Restoration The latch out can be restored by moving the machine toward the opposite position until all four vital sensors are OFF and then returning to the original position this will occur only in the automatic latch out jumper mode and only if the point and lock sensors are properly indicating The latch out feature can also be completely disabled by placing the junction box jumper in the disabled latch out position The ECC also continuously monitors the states
69. tion and two for locking detection and two optional auxiliary non vital sensors are terminated via a six way cable grip This termination method allows for convenient replacement of any individual sensor in the system The junction box also has two jumper sets that provide the ECC box with the configuration information for determining which point is normally closed left hand point closed LHPC or right hand point closed RHPC and which type of latch out configuration has been selected manual restoration automatic restoration or latch out disabled completely 2 2 WAGO Terminal Strip The ECC box is connected to the WAGO terminal strip in the motor compartment with two plug connected cables TB1 and TB2 Both plug connectors are keyed differently so they cannot be interchanged on the ECC box The WAGO terminal strip is the integration point of the ECC system where all field wires for switch indication and the wayside battery feed to the ECC system The WAGO terminal strip is also the termination point for the machine s cycle counter and the optional local remote request switch In addition it is equipped with a series of 14 gas tube lightning arrestors for lightning protection 2 3 Motor Compartment The motor compartment is equipped with an eight way AAR binding post strip for field motor power cable wires and motor control unit termination Two of the AAR posts are strapped with a gold nut to open motor power to the machine T
70. to take into account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved ASTS USA spare parts are used as replacements SM 6263A Rev 3 November 2010 i A Revision History AnsaldoSTS Revision History February 2002 Initial Issue April 2005 Incorporated ECO EM 1771 Update Internal Wiring Diagrams Incorporated ECO EM 1813 Updated Motor Compartment parts list and drawing Incorporated ECO EM 1852 Update Internal Wiring Diagrams Incorporated ECO EM 2075 Updated Internal Wiring Diagrams Incorporated ECO 139565 277A Changed the value of the resistor between Terminals 33 and 34 of the WAGO terminal block Incorporated ECO 139712 155 Updated Internal Wiring Diagrams the PCB for the junction box and the parts lists April 2006 Incorporated ECO EE 2013 added note on Figures 4 11 and 4 12 that deals with motor control wiring Incorporated ECO 140050 4 Revised figures 4 10 4 11 and 4 12 to remove the two arrestors on the AAR terminal block in the motor control compartment and replaced them with arrestor PCBs Incorporated CRS01346 Placed revised drawing into Figure 6 2 Changed the
71. ularly useful when conducting monthly inspections In order for this function to work however the wayside must be so configured Basically the two toggle switches in the machine L R and N R interface with the local control panel providing the ability to control the machine as though operating directly from the local control panel The local remote L R switch normally is to be in the remote position When placed in the local position battery is routed to Terminal 26 The local control panel is thus activated to receive commands from maintenance personnel at the machine The second switch N R is a center OFF spring return toggle When held in the N position the machine is electrically driven from the wayside controller to the normal position If the switch is released before the stroke is complete the motor will coast to a stop 4 10 SM 6263A Rev 3 November 2010 D e AnsaldoSTS Installation CAUTION The LOCAL REQUEST position will override the dispatches control of the machine It therefore is important to return the L R switch to the Remote position upon completion of maintenance 8 Terminals 27 through 31 are for termination of the MCU and are also used to terminate the cycle counter 4 4 2 Motor Control ON MOTOR FRONT and ON MOTOR REAR are used to turn off motor current at the end of the stroke For example if the motor is turning to produce motion of the lock box toward the motor compartment front end
72. ured from ASTS USA with the switch point closest to the machine designated as the normally closed or normal point Therefore all right hand machines are shipped with the jumper in the RHPC position and all left hand machines are shipped with the jumper in the LHPC position Because the same terminals on the WAGO terminal strip are always used for normal and reverse indication regardless of the RHPC LHPC jumper position it is necessary to move the jumper to the opposite position if the normally closed switch point is furthest from the machine installation 4 1 2 Latch Out Jumpers The latchout jumper for all ASTS USA M style switch machines is set for either the automatic manual or disable function This configuration is set at the factory based on customer preference at the time the order was placed To change this configuration remove the junction box cover and reposition the jumper See Section 3 1 1 for a detailed explanation of each jumper function See also Figure 4 1 for the various jumper positions 4 1 3 Changing the Jumper Configuration 1 Disconnect plug connectors TB1 TB2 and JB1 from the ECC by rotating the coupler collar counterclockwise and extracting the male end 2 Ensure that the machine is in the full locked position with the lock box extended toward the gearbox 3 Remove the internal point detector bar target by removing the Allen head set screw and socket head cap screws securing the target and sliding
73. vember 2010 74 AnsaldoSTS Troubleshooting Problem Cause Solution _ Verify proper linear adjustment of the PD sensor and verify proper 0 075 vital sensor air gap to obtain proper sensor response Remove any loose metallic objects or obstructions from the vicinity of the sensors Ensure that LS1 and PS1 and LS2 and PS2 are terminated correctly in the Junction Box They must work as a unit 10 The ECC does not latch A Machine is not EE 1 Ensure machine is fully locked A latched out condition out when point detector EE will only occur if the machine is fully locked and the target is removed from switch point moves away from the stock rail in front of target face B ECCis configured to 1 Move latch out configuration jumper in the junction and restored disable the latch out box from the disable to the manual or automatic feature jumper positions C Point detected and 1 Ensure proper linear adjustment of the PD sensors to point locked sensors indicate the presence of the point detector bar target for that corresponding and ensure that the machine is in the full locked position are not ON position prior to restoring the latched out condition i e the machine is not fully thrown and locked or the PD sensors are out of adjustment D Defective latch out 1 To verify move latch out configuration jumper to the restoration pushbutton automatic position in the junction box and manually on ECC cycle the mac
74. vention lt onsistent with Gear Ratio and f Retrofit of M23 with ECC N24 N l TO B24 gt 5 Wire Wound Field Motor For 3 Wire to 2 Wire Conversion FROM Connect together and return to N24 for 2 Wire Control 3 Eliminate for 2 Wire Control M23 with ECC Retrofit 1 B24 N Observe Polarity Convention n Consistent with Gear a io an 2 Retrofit of M23 with ECC N TO UL NEN Normal amp Reverse Motor Cut Out J Hand Throw Symbols Motor Cut Off N24 y Figure 4 9 Wiring Changes from 3 Wire and 5 Wire to 2 Wire Motor Control For 5 Wire to 2 Wire Conversion SM 6263A Rev 3 November 2010 4 25 Ny Installation y AnsaldoSTS N Y AnsaldoSTS 4 26 SM 6263A Rev 3 November 2010 D e AnsaldoSTS RED ORANGE YELLOW Auxiliary Sensor 1 Auxiliary Sensor 2 VIOLET BLACK WHITE BROWN WHITE RED WHITE ORANGE WHITE YELLOW WHITE Sensor 1 Sensor 2 Sensor 1 Sensor 2 J2 Heater Top View Tape lead to harness only for 115V source for field applications with 115V source disconnect 7 for 230V and connect this lead to terminal 7 Combine leads and connect to terminal 8 Connnect lead to terminal 7 BU BR BU BR BU BR BU BR LOCK POINT AUX 1 2 2 2 BU BR BU BR POINT AUX 1 LOCK 1 Les 0 ON 0 FE

SM-6263A - Ansaldo STS

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