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SM-6263 - Ansaldo STS

1. 4 5 4 5 5 Motor Cut Out Contacts 4 5 4 6 Repair Procedures eter Eri ee Ee ERR EE OE E 4 6 5 SHOP MAINTENANCE ven uncon oneto 5 1 5 1 Special Tool mianra neea a EE E A faba en adresaro 5 1 5 2 CIGANING m EE 5 1 5 3 Inspection xai o Ere Ee IERI e UR ei 5 1 ds b RE e e D E DRM MSS 5 2 5 4 1 Removal of Motor Brushes 5 2 5 4 2 Removal of Motor des cte cna Ee a Fees ee aka Sea gres 5 2 5 4 3 Removal of Friction Clutch Assembly 5 2 5 4 4 Removal of Circuit Controller 0020001000 5 3 54 5 Gearbox Removal M F iarainn Du aya u TN dn 5 4 5 4 6 Removal of Main Crank 2 2 00000 0 2 000 00 5 4 5 4 7 Removal of Selector Clutch a aa 5 4 5 4 8 Removal ot Worm Shaft ss are tao muu eio rer elem pde ak iat 5 4 54 9 Final Dis ssembly 5 ELA igs He Ee epu 5 5 5 4 10 Gearbox Dismantle M 23A 23 5 5 5 5 MASSOMIDIVi EH 5 5 5 5 1 Reinstallation of Gearbox 3 5 5 5 5 2 Gearbox Reassemble
2. SHS L AES run a LAS Figure 2 2 Typical M 23A and M 23B Machine Application SM 6263 Rev 7 June 2009 2 3 PU uw Installation and Adjustments AnsaldoSTS 12414 20 TOP VIEW H 296 i TACITO IKI Alam k u dron 15 3 16 UNFINISHED a LUGS 1 cay 5 HL i BO o FINISHED 18 250 o LUGS 18 238 16 7 8 1 21 3 4 4616 3 42 8 1 1 LI SHORT 5 COVER 7 1 2 6 1 2 LONG i 5 3 1 2 SIDE VIEW END VIEW Figure 2 3 Typical M 3 Mounting Plan 2 4 SM 6263 Rev 7 June 2009 5 B AnsaldoSTS Installation and Adjustments 5 312 12 14 20 7 112 6 1 2 Shit ee 7 FOR 78 BOLTS I e I 718 PIN LI M TOP VIEW m dam A 79 9 9 9 9 gt 15 3516 Fi UNFINISHED a ias Li 2 u Bm 5 1 718 815 N 18250 FINISHED n HAND le 18238 LUGS THROW 16 18 gt Tegel i o par Fl ama 2148 5 UL SHORT ii COVER LONG COVER 34 18 BAR SIDE VIEW 10147 SS so 2 15 16 d END VIEW Figure 2 4 Typical M 23A and M 23B Mounting Plan SM 6263 Rev 7 June 2009 2 5 n Installatio
3. 3 12 Schematic Diagram of Point Detector Parts in Mid Stroke Position 3 12 Schematic Diagram of Point Detector Parts in Reverse Position 3 13 Schematic Diagram of Point Detector Parts in Reverse Position and Latched Up 3 13 Sectional View of M 23A Gearbox a 3 16 Sectional View of M 23A Gearbox Looking from Motor 3 17 Sectional Views of M 23A Dual Control 3 20 Motor Cutout Contact Assembly M 23A and M 23B Machines 3 21 Hand Throw Bevel Pinions for M 23A and M 23B Switch Machines Lever Interlock 3 22 Heaters for Circuit Controller and Motor Compartments 3 24 Friction Clutch 2 aeiae aaae ae rennen nennen nnns 5 3 Friction Clutch Assembly and Special Wrench for Packing Gland Nut 5 10 Lubrication Diagram for Switch Machine 5 15 Lubrication Diagram for M 23A and M23 B Switch Machines 5 15 SM 6263 Rev 7 June 2009 AT Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 5 9 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Fi
4. 2 1 2 5 Point Detector Bar Installation and Adjustment sse 2 6 2 6 Lever Stand Adjustment GA EA Ede ra Leg o NO 2 6 2 7 Electric Connections and Control Wiring 2 7 2 65 Initial b brication 4 gi nete bah te olea te ale o 2 12 29 Lever Position and lriterloCk eee te iS eee etg aas 2 13 2 10 Prior To Placing Machine In Operation nnne 2 15 2 11 Supplemental Information U nennen nennen 2 15 2 11 1 Inverting the Lock 4444442444 nnns retentis snnt 2 15 2 11 2 Shifting the Indication Cams 00 eerte nnne 2 16 2 11 3 Converting Between High and Low Voltage 2 17 2 11 4 Converting Between Five and Three Wire 2 17 3 HOPERATION rni 3 1 3 1 Switch Operating and Locking Mechanism sese 3 1 3 2 Switch Point Locking tisha ag AGRA ILIA ROLO 3 5 3 3 Giry Controller PEE ER 3 5 39 1 Indication CONTACTS e ort eai KEEL Sec NR DOG iaa 3 8 3 3 2 Motor Control Contacts ret ede teo MA bem 3 10 3 4 Detector esa dene e dte teta tete t n 3 10 3 5 Gear Train ter n eme 3 14 3 6 Operation By Hand Crank 3 18 3 7 Dual Control Mechanism M 23A and M 23B 3 18 3 7 1 Operation By Selec
5. Reassemble collar E with chamfer down on top of crank and with hand throw lever vertical apply hand throw bevel pinion D engaging tooth marked R for right hand assembly or L for left hand assembly with punched marked master tooth space on hand throw gear F Carefully place hand throw lever in Normal position Be sure that bevel pinion remains in line With selector lever in MOTOR position rotate friction clutch housing so that motor clutch teeth are fully engaged SM 6263 Rev 7 June 2009 AT AnsaldoSTS Shop Maintenance e k 5 5 3 Reapply top bearing assembly and secure with hold down bolts A1 Motor cutout push rod should be held back to clear the adjusting rod until top bearing is down Apply top bearing bushing C2 rectangular key washer B2 and tighten castle nut B1 firmly then back off to nearest cotter hole and apply cotter after operating machine by hand throw lever to be sure that mechanism does not bind Check adjustment of motor cutout push rod Contacts should open when end of selector lever has been raised approximately 6 from the horizontal motor position Readjust both yoke eccentric bushings as described in Section 5 7 3 then secure by tightening bolt G firmly Check that 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 lock washers and that all cotters are
6. 0520 0609 0613 0616 0617 0619 0620 N451161 1701 N416001 Machine Suffixes 01 04 N416007 01 N416002 Machine Suffixes 01 04 Circuit Controller N451160 Machine Unless Noted Otherwise Suffixes 0512 0513 0533 0534 0537 0538 0544 0545 1209 1210 0623 0624 0649 0650 N285638 001 N416001 Suffixes 03 04 Suffixes 0504 0505 0514 0543 0546 0547 _ 0647 0648 285638 004 N451160 Suffixes 1217 1218 N451160 Suffixes 1201 1202 All Other Suffixes N451160 N416001 N416002 Screw Name Plate Screw No 6 x 1 4 Plate Not Used I i Not Used Screw 1 2 13 x 12 Guide Roller Guide Roller Locking Bar Slide Bar Cam Includes Studs Ref 106 and Rollers Ref 107 N146444 and 108 Operating Bar Lug N451160 Suffixes 0543 0546 0547 Only Operating Bar Lug All Other Suffixes Wearing Bracket Conduit Conduit Outlet Terminal Board Inc 1 Ref 24a 25 Ref 101 and 25 Ref 105 SM 6263 Rev 7 June 2009 6 11 5 Configuration Guide and Parts List AnsaldoSTS J048136 Pipe 28659 109 NotUsed 0 0 0 00 P 7 J050092 M286594 Motor Cutout Push Rod Spring M286589 Lock Rod Cover N269671 31 6 6 12 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List Wire Clamp For Harness Not Shown 66 Busing 6 2962 68 Bot 1 1 1 1 10500
7. 51160 0518 N451160 0517 20VDC 5281 26sec 5Wire 451160 0520 51160 0519 R 110VDC 1894 45sec 5Wire N451160 0535 N451160 0586 110 VDC 189 1 45sec 3Wire N4511600543 110VDC 189 1 45sec 5Wire 451160 0547 N451160 0546 20VDC 3601 15sec 5Wire 451160 1203 110VDC 189 1 45sec 3Wire 451160 1208 110VDC 189 1 45sec 5Wire 451160 1224 51160 1223 20VDC 5281 26sec 3Wire 51160 1226 51160 1225 20VDC 3601 8sec 3Wire SM 6263 Rev 7 June 2009 6 3 n Configuration Guide and Parts List AnsaldoSTS Part Number Configuration Control Right Hand Left Hand Ref Wiring N416001 01 N41600102 T W X 3 Wire N416001 04 N41600103 20 VDC 528 1 Table 6 4 M 23B Switch Machine Assemblies Part Number Configuration Control Right Hand Left Hand Ref Wiring N451160 0601 N451160 0602 E F 5 Wire N451160 0604 51160 0603 20VDC 528 1 26sec 5Wire N451160 0605 51160 0606 20VDC 3601 15sec 5Wire N451160 0610 N451160 0600 110 VDC 1891 45sec 5Wire N451160 0615 51160 0614 GM 20VDC 5281 26sec 5Wire N4511600607 C D 110 VDC 1891 45sec 5Wire N4511600608 20VDC 3604 15sec 5Wire N451160 0623 N451160 0624 20VDC
8. Within the scope of the attached manual it is impossible to take into account every eventuality that may arise with technical equipment in service Please consult 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 6263 Rev 7 June 2009 5 Revision History AnsaldoSTS Revision History DATE NATURE OF REVISION TIT Augustos 2 February 1992 227 mm ml September1999 7 Kwa iu February 2005 Added information to Appendix A for 3 wire control Incorporated ECO EM 1060 Updated part numbers on bushings in the gearboxes Incorporated ECO EM 1830 Added the oil seal PN J7900260003 to the parts lists for the gearbox Incorporated ECO EM 1996 Incorporated detailed information on motor brush replacement Incorporated EM 2045 Updated information on motor frame Incorporated ECO EM 2098 Updated information on the new hand throw lever for the M 23A and M 23B switch machines Incorporated ECO 139712 225 Added Appendix B Information on the 2 Wire Control for GRS Replacement Machines Incorporated ECO 139712 228A Added the tie bars to the parts list for the circ
9. 528 1 26sec 5Wire N451160 0626 51160 0625 20VDC 528 1 26sec 5Wire N451160 0627 51161 0628 CD 110 VDC 1891 45sec 3Wire N451160 0632 451160 0631 H 110 VDC 1891 45sec 3Wire N451160 0633 N451160 0634 CD 20VDC 528 1 26sec 3Wire N451160 0636 N451160 0685 CD 110 VDC 1891 45sec 3Wire N451160 0638 N451160 0637 110 VDC 1891 45sec 5Wire N451160 0639 51160 0640 CD 20VDC 360 1 15sec 3Wire N451160 0642 51160 0641 20VDC 528 1 26sec 3Wire N451160 0644 51160 0643 20VDC 5281 26sec 5Wire O M OO PI P O Tm g T s O 6 4 SM 6263 Rev 7 June 2009 AnsaldoSTS Configuration Guide and Parts List 6 1 M 3 Switch Machine Single Switch Parts List Table 6 5 contains the parts list for the switch machines listed in Table 6 2 M 3 Figure 6 1 shows a location diagram for the listed parts Table 6 5 M 3 Switch Machine Single Switch Parts List 1 Notus d Base Complete RN s mo Base Complete Suffixes 0301 0304 0307 0310 0313 0318 0340 0341 N291056 002 Suffixes 0305 0306 0311 0312 0319 0320 0322 0323 N294752 001 0326 0329 4001 4004 Suffixes 0324 0325 0332 0337 4005 4006 N451160 1601 Suffixes 0342 0345 N291056 Suffixes 0
10. BOLT E A4 BOLT F e B1 NUT NETS ENS B2 WASHER TON a C BEARING A3 EY ES C1 KEY C2 BEARING BUSHING D PINION E COLLAR F GEAR F1 SET SCREW G BOLT G1 YOKE BUSHING H YOKE SUPPORT K LEVER SUPPORT M BEARING N YOKE P PIN Figure 3 12 Sectional View of M 23A Gearbox SM 6263 Rev 7 June 2009 EN 7 AnsaldoSTS Operation F P B2 BI c2 H Right Hand E 227 9 _ l S Side View XZ ay S 2 lt lt b La SS TPR 7 N an p Z 2 aLa yy A E E mg i 2 ES kda mid A x X tr P P P Fg lt TOO lt VA N SSeS VI gt UU gt Bx 7874 EC a7 E IS ES Figure 3 13 Sectional View of M 23A Gearbox Looking from Motor End The friction clutch housing has a tubular neck supported in an Oilite bushing pressed into the gearbox bore The inside diameter provides slight clearance for the worm shaft The housing has a felt washer and an oil seal to prevent seepage of oil into the friction clutch The worm shaft is grooved and the housing has ribs to drive alternate friction discs that are compressed by the action of the heavy coil spring This spring force is contained between the adjusting nut and Oilite thrust plate supported on the tapered shoulder on the worm shaft Note that the clutch gear hub has a three finger engagement with the
11. Extensive cleaning of the switch machine is not required However it is important that the circuit controller compartment be cleaned at the time of inspection to ensure proper electrical operation Clean the circuit controller compartment as outlined in Sections 4 2 1 and 4 2 2 SM 6263 Rev 7 June 2009 4 3 Field Maintenance 4 AnsaldoSTS 4 2 1 Equipment Materials Required The following cleaning agents and materials are required to clean the circuit controller compartment a Water based degreaser b Lint free cloths 4 2 2 Procedure Clean the circuit controller compartment as follows a Dampena lint free cloth with household degreaser and wipe motor control indication and motor cutout contact springs free of any accumulated dirt Dry with a clean lint free cloth b Repeat step for motor control segments indication cams yoke operating levers and point detector connecting rods crank and crank springs c Dry with a clean lint free cloth NOTE If the contact springs motor control segments or indication cams show any signs of pitting corrosion or general deterioration they must be replaced Refer to Section 5 d Lubricate cleaned areas per instructions provided in Section 5 6 4 3 Lubrication After the switch machine has been inspected and cleaned it must be lubricated to ensure optimum operation Refer to Section 5 6 4 4 Switch Machine Performance Test Conduct a performa
12. 7 4 Contactor Assembly N451161 5303 Machines manufactured before October 2005 use contactor N451161 5303 Machines manufactured beginning October 2005 use contactor N410011 01 see Section 7 5 Table 7 4 Contactor Assembly N451161 5303 Parts List Description Part No Screw 6 32 x 1 4 J525055 Washer 6 Lock Screw 8 32 x 1 RH Washer 8 Lock Nut 8 32 Screw 8 32 x 5 8 RH Shock Mount Contactor Top Mount Plate Bottom Mount Plate Snub Washer Jumper Clip Burndy HP 8N Screw 8 32 x 1 1 4 Round Head X X relates to N Y Y relates to R 7 6 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Two Wire Control for ALSTOM GRS Replacement Machines Figure 7 4 Contactor Assembly N451161 5303 Parts Location SM 6263 Rev 7 June 2009 7 7 5 3 Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS Figure 7 5 Contactor Assembly N451161 5303 X and Y Label Location 7 8 SM 6263 Rev 7 June 2009 5 AnsaldoSTS Two Wire Control for ALSTOM GRS Replacement Machines 7 5 Contactor Assembly N410011 01 Machines manufactured beginning October 2005 use contactor N410011 01 Machines manufactured before October 2005 use contactor N451161 5303 see Section 7 4 Table 7 5 Contactor Assembly N410011 01 Parts List 60 Screw 1 420x5 8 Cap SS 5000970110 80 Jumper Contactor 1
13. 7 AnsaldoSTS Shop Maintenance The slide bar can be removed through the motor compartment after first removing the lock box and the motor 5 4 9 Final Disassembly After removing all major subassemblies per the above paragraphs continue to disassemble the remaining components refer to Figure 6 1 or Figure 6 2 and associated parts list for parts location and identification Disassemble only to the degree necessary to repair the machine 5 4 10 Gearbox Dismantle M 23A and M 23B Refer to Figure 3 12 and Figure 3 13 remove covers for gearbox and motor compartment and use as receptacles for parts removed Place hand throw lever in Normal position and selector lever in MOTOR position b Remove 1 2 13 bolts Al 2 and 4 securing top bearing C yoke support lever support K and lever shaft bearing M respectively c Remove castellated nut B1 and washer B2 from top of main crank and lift top bearing C from dowel pins carefully to prevent bending Remove the rectangular key Cl Figure 3 12 from top bearing bushing C2 hand throw pinion D and spacing collar E on top end of crank Lift hand throw lever to vertical position and remove set screw 1 from hand throw bevel gear F Remove lever assembly and lift out hand throw bevel gear d Remove 1 2 13 x 5 1 2 bolt securing yoke eccentric bushings G1 and then remove yoke support H Positions of eccentric bushings should be noted and care should be taken to
14. Regular and systematic lubrication is recommended however the lubrication interval depends on the operating frequency and the climate and location conditions and therefore can be established from experience by the Supervisory Department SM 6263 Rev 7 June 2009 77 AnsaldoSTS Table 5 3 Lubrication Specifications for M 3 M 23A M 23B Switch Machines Point of Application Type of Lubricant amp ASTS USA Spec Pressure Gun Grease Spec M 7650 01 Known Products Complying With Spec Alemite Solidified Oil 432 Alemite Temprite Solidified Oil E P Prime Mfg Co Shop Maintenance Grease Fittings Grease Gun Apply until surplus is visible at edges of bearing Either Pressure Gun Grease Spec M 7650 01 OR Heavy Oil Viscosity at 210F 120 to 200 and rear end lubricant SAE 140 Paddle Auto transmission Pour or Surface Paddle Medium Body Oil Viscosity at 130F 185 to 220 Low Temperature Oil Spec M 7610 02 Low Temperature Lubricating Oil Spec M 7652 3 Automobile Engine Oil SAE 30 Low Temperature Lubricating Oil ASTS USA Lubriplate 5555 Fiske Brothers Refining Co Oil Can Bearings amp Oil Cups Pour Recess on top crank bearing Pour Spur Gear Teeth A few drops periodically as required Fill recess periodically as required Apply very light film to all contact segments at frequent intervals after cleaning Apply light coat to teeth as
15. aa 6 23 6 6 M 3 M 23A and M 23B Standard Base 6 27 6 7 M 3 M 23A and M 23B Motor 6 27 7 TWO WIRE CONTROL FOR ALSTOM GRS REPLACEMENT MACHINES 7 1 Tle Configuration GUIGe Pier DR Den RA UB ie ERI Ta 7 1 7 2 Switch Machine Assemblies 7 1 7 3 Switch Machine Parts List seecssssssssssssssssnsansnsssssssessatsnssssssssssnsanannnssnnsess 7 1 7 4 Contactor Assembly N451161 5303 aras 7 6 7 5 Contactor Assembly N410011 01 7 9 7 6 Motor Assembly o aL AA LA GU LA ANALI ao 7 12 8 RAIL TEAM AND TECHNICAL SUPPORT 4 1220 21 8 1 SM 6263 Rev 7 June 2009 V A Table of Contents AnsaldoSTS Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 vi List of Figures M 3 Switch Machine Outline Diagram I I n n 1 4
16. required Worm Gear Pour in Fill only Compartment to top of worm gear 5 7 Adjustments 5 7 1 Point Detector Point detector rollers should be maintained to clear the small diameter of the point detector bar by not more than 1 32 If necessary adjust the screwing eyebolts 19 Figure 6 5 in or out screws 67 must first be removed Use point detector gauge N295326 to check latch operation in normal and reverse switch positions See SM 5453 for instructions for usage of the point detector gauge Add a sufficient amount of shims as required to enable latch to clear the top of the yoke in both switch positions and latch properly Check indication contacts in latched positions to insure that they are open a minimum of 3 64 SM 6263 Rev 7 June 2009 5 17 A Shop Maintenance AnsaldoSTS 5 7 2 Motor Cutout Contacts See Figure 5 5 for a detail view of the motor cutout contact and actuator arrangement 5 7 2 1 M 3 Switch Machine Motor Cutout Contacts Inspection a b Remove the circuit controller cover Make sure the hand crank cover 1 closed Inspect the gap between F and H of Figure 5 5 The preferred gap is 1 16 The gap cannot be more than 1 8 Open the hand crank cover and inspect the gap in detail H and K of Figure 5 5 The minimum gap should be 1 8 A larger gap is acceptable For machines with latch release lever G close the hand crank cover so that the hasp engages the notch i
17. the hand throw lever through the hand throw pinion The selector clutch slides along splines on the shaft of the main crank and is shifted up or down by the selector lever To permit the selector lever stroke to be completed even though the top tooth of the selector clutch may not be in alignment with the tooth space in the hand throw pinion hub when shifting from motor position shown to hand throw position connection between the selector lever and the selector clutch is made through a coil spring mounted on the selector clutch NOTE In Figure 1 2 the top tooth is shown in alignment with the tooth space in the hub of the hand throw pinion because the switch and the hand throw lever are both in the Normal position There may be times when the switch is blocked mid stroke by an obstruction so that the main crank will not be in Normal position and of course if the last motor operation left the switch in the reverse position the teeth likewise are not aligned The selector clutch will snap into engagement with the hand throw pinion when the hand throw lever is operated to a position corresponding with the switch position This spring connection acts similarly when returning the selector lever to the motor position however in this case it is the motor that must be operated to align the worm gear hub teeth to receive the selector clutch teeth Observe that the main crank remains engaged with its original connected driving elements un
18. 0534 0538 0548 1209 1214 1218 1223 N287074 N416001 Machine Suffixes 02 03 Suffixes 0510 0514 0520 0523 0527 0529 0535 0540 0541 0545 1204 1212 1219 1222 N291057 N293975 N287073 0001 Suffixes 0511 0519 0524 0528 0530 0536 0539 0542 0543 0544 1201 1203 1205 1208 1211 1220 1221 N287073 M 23B Gearbox Complete N451160 Machine Unless Noted Otherwise Suffixes 0601 0605 0621 N287075 0001 N416002 Machine Suffix 03 Suffixes 0602 0606 0618 0622 0640 0651 0653 N287075 N416002 Machine Suffix 04 Suffixes 0603 0607 0614 0624 0625 0629 0634 0641 0643 0645 0647 N416002 Machine Suffix 02 Suffixes 0604 0608 0615 0623 0626 0627 0630 0633 0636 N287077 N287077 0001 6 10 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List B 0642 0644 0646 0648 0650 0656 0658 N416002 Machine Suffix 01 Suffixes 0609 0612 0616 0617 0619 0628 0631 0635 0637 0649 0655 0656 N287076 Suffixes 0610 061 1 0613 0620 0639 0652 0654 N287076 0001 N416002 Machine Suffix 02 DC Motor Complete N451160 Machine Unless Noted Otherwise Suffixes 0501 0502 0507 0509 0601 0602 0605 0606 0618 451161 1702 Suffixes 0503 0506 0512 0513 0515 0518 0603 0604 0607 0608 0614 0615 451161 1703 Suffixes 0510 0511 0514 0519
19. 1s shown by Figure 3 2 and Figure 3 3 Roller x on crank X acting in groove y has moved switch operating bar Y to the reverse position and secured it against back thrust lug x has come into contact with roller z during the last 40 degrees of rotation of crank X thus driving slide bar Z to its full reverse position Connection to the switch points may be made at either end of switch operating bar Y to suit the particular switch layout The position of the switch points is checked and secured by the action of the lock box SM 6263 Rev 7 June 2009 3 1 2 Operation 77 AnsaldoSTS SLIDE BAR BOTTOM VIEW SLIDE BAR Z Figure 3 1 Schematic Diagram of Switch Operating Mechanism 3 2 SM 6263 Rev 7 June 2009 N 77 AnsaldoSTS Operation MOTOR END ROLLER 22 SLIDE CIRCUIT CONTROLLER BAR 13 OPERATED BY THESE RACK TEETH ROLLER Z ROLLER Z1 CENTER LINE OF CIRCUIT CONTROLLER LOCK RODS WIDE UPPER XI ROLLER X 1 LOWER LOCKING DOG RADIAL PORTION STRAIGHT PORTION IS SWITCH OPERATING BAR LUG UPPER LOCKING GROOVE Y k 3 DOG Nu 2 b SWITCH OPERATING ROD RIGHT HAND WIDE NOTCH LOWER NARROW NOTCH KOMER DETAIL A NOTE DIRECTION OF MOVEMENTS SHOWN ARE FOR A LEFT HAND SWITCH MACHINE THE DIRECTION OF MOVEMENTS ARE REVERSED FOR A RIGHT HAND MACHINE THE SLIDE BAR AND LEFT HAND OPERATING BAR STROKE TIMING RELATIO
20. 2 For right hand operation remove lead A to B 3 Remove lead 10 to 35 4 Remove lead D to 5 5 Add lead D to A e Five to Three Wire Control 20 VDC 1 For left hand operation add lead C to 34 SM 6263 Rev 7 June 2009 2 17 5 3 Installation and Adjustments AnsaldoSTS 2 Forright hand operation add lead B to 34 e Three to Five Wire Control 20 VDC 1 For left hand operation remove lead C to 34 2 For right hand operation remove lead B to 34 NOTE Control wiring logic must be in correspondence with Figure 2 5 through Figure 2 8 2 18 SM 6263 Rev 7 June 2009 V 77 AnsaldoSTS Operation 3 OPERATION 3 1 Switch Operating and Locking Mechanism The main crank drives both the switch operating bar and the slide bar The latter carries the lock box with its locking dogs which enter notches in the lock rods when the switch points are in proper position and also carries rack teeth which operate the circuit controller Assuming the machine to be at one end of its stroke operation to the opposite end of the stroke involves rotation of the main crank by the motor or by the hand throw lever As the main crank turns it first shifts the slide bar so as to withdraw the locking dog from the lock rod notch before the switch points start to move then the main crank holds the slide bar in the mid position both locking dogs clear of the lock rods while driving the switch operating bar full stroke to its o
21. 511615802 90 Washer 5 16 Plate SST 4 75120 0113 SM 6263 Rev 7 June 2009 7 9 lt Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS DETAIL A F410011 R1 DETAIL A Figure 7 6 Contactor Assembly N410011 01 Parts Location SM 6263 Rev 7 June 2009 7 10 AT Z AnsaldoSTS Two Wire Control for ALSTOM GRS Replacement Machines 29 000 Figure 7 7 Contactor Assembly 410011 01 X and Y Label Location SM 6263 Rev 7 June 2009 7 11 5 3 Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS 7 6 Motor Assembly Table 7 6 Motor Assembly N451161 1706 Parts List 60 Washer 17 64 9 16 Copper 0047818 80 Nik i2 st 90 NotUsd 111 NotApplicabe 7 12 SM 6263 Rev 7 June 2009 2 AnsaldoSTS Two Wire Control for ALSTOM GRS Replacement Machines amp ij ch Z UT HS p lt k 8 LJ SEE VIEW A LEAD RUNNING THROUGH CLIP VIEW A BRUSH AREA WITH COVER REMOVED Figure 7 8 Motor Assembly N451161 1706 Parts Location SM 6263 Rev 7 June 2009 7 13 N
22. Box Complete 189 1 Gear Ratio 360 1 Gear Ratio 528 1 Gear Ratio Not Used Ec Gear Box Includes Bushings amp Oil Seals Items 44 50 Top Bearing Worm and Shaft Clutch Housing Clutch End Plate 7 Clutch Plate Clutch Plate Clutch Disk 10 Clutch Spring 11 Clutch Adjusting Nut 12 Felt Washer 12 Oil Seal 13 Gasket 14 Plate 16 Gasket 17 Bearing Cap 18 Clutch Gear Comp Includes Bushing Item 51 19 Hand Crank Bevel Gear 20 Hand Crank Bevel Pinion 21 Shaft 22 First Reduction Gear 360 1 Gear Ratio 22a First Reduction Gear 528 1 Gear Ratio 23 First Reduction Gear 189 1 Gear Ratio 24 Second Reduction Gear 360 1 Gear Ratio 24a Second Reduction Gear 528 1 Gear Ratio 25 Spacer 26 Spacer 27 Shaft End Plate 28 Dowel 29 Washer 30 Gear Train Cover Complete 31 Shai B NE DEC E 8 10 pau 12 _ 16 mus s EON 20 21 22 22a 23 24 24a 25 26 27 28 29 30 pow 6 16 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List SM 6263 Rev 7 June 2009 6 17 A Configuration Guide and Parts List AnsaldoSTS VIEW OF 189 TO 1 GEAR RATIO ASSEMBLY 4 3 18 2426 STM o 20 Pd mud kod A 16 38 42 19 39 5029 51 4612 5 10 15 12A Figure 6 3 M 3 S
23. CONTROL WIRING To Control Circuit To Control Circuit WRI PN 150BM WRPR Relays N24 SWITCH MACHINE MAIN TERMINAL BOARD SWITCH MACHINE MAIN TERMINAL BOARD POLAR NEUTRAL B C NOTE EXTERNAL CONNECTIONS ARE SHOWN TO THE MAIN TERMINAL BOARD FOR A SWITCH HAVING THE RIGHT HAND POINT NORMALLY CLOSED FOR SWITCH HAVING THE LEFT HAND POINT NORMALLY CLOSED INTERCHANGE THE EXTERNAL LEADS TO TERMINALS B AND C AND TO TERMINALS 5 AND 10 ON THE MAIN TERMINAL BOARD Figure 2 5 M 3 M 23 Low Voltage DC Machines Five 5 Wire Control 2 8 SM 6263 Rev 7 June 2009 A AnsaldoSTS Installation and Adjustments CIRCUIT CONTROLLER A INTERNAL WIRING CIRCUIT CONTROLLER MAIN TERMINAL BOARD 9 a OED CONTACTS CONTROLLED BY SELECTOR SHUNTING STRIP DIRECTION OF NEXT ROTATION NOTE NUMBER IN CIRCLE REPRESENTS NUMBER OF TERMINAL NUMBER NOT IN CIRCLE SHOWS NUMBER OF TERMINAL TO WHICH OTHER END OF WIRE IS CONNECTED CONTROL WIRING To N WR To N WR Control Circuit Control WRI Circuit PN 150BM PN 150BM Relays SWITCH MACHINE Al TERMINAL BOARD POLAR NEUTRAL B NOTE EXTERNAL CONNECTIONS ARE SHOWN TO THE MAIN TERMINAL BOARD FOR A SWITCH HAVING THE RIGHT HAND POINT NORMALLY CLOSED FOR SWITCH HAVING THE LEFT HAND POINT NORMALLY CLOSED INTERCHANGE THE EXTERNAL LEADS TO TERMINALS 5 AND 10 AND TO TERMINALS B AND C ON THE MA
24. Operating Characteristics Table 1 2 Operating Characteristics General Information 110 VDC 189 1 110 VDC 360 1 20 VDC 360 1 20 VDC 26 34 seconds 528 1 Voltage at motor terminals Switch over time measured in accordance with AREMA AAR Manual Part 12 2 5 These times will vary depending upon motor terminal voltage and machine operating load and conditions 1 4 3 Electrical Data Table 1 3 Electrical Data Motor Part No Motor Voltage J717216 0301 110 VDC J717216 0302 20 VDC J717216 0303 20 VDC J717216 0501 20 VDC J717216 0502 20 VDC J717245 0002 20 VDC M451161 5701 110 VDC Heaters work with any switch machine and are dependent on the application 15W 115 VAC or VDC 15W 115 230 VAC or VDC 15W 24 VDC SM 6263 Rev 7 June 2009 1 3 lt RET General Information AnsaldoSTS CIRCUIT CONTROLLER GEAR MOTOR COMPARTMENT BOX COMPARTMENT SLIDE BAR SWITCH MAIN HAND CRANK Ei idm CRANK INSERTED HERE LOCK BOX MOTOR ROTATES FOR POINT WORM GEAR DETECTOR ROD LOCKING DOGS CIRCUIT CONTROLLER IS OPERATED BY THESE RACK TEETH INDICATION CONTACTS MAIN CRANK ROLLER ARE AFFECTED ALSO BY POINT DETECTOR Figure 1 1 M 3 Switch Machine Outline Diagram 14 SM 6263 Rev 7 June 2009 A uw AnsaldoSTS General Information CIRCUIT CONTROLLER GEAR MOTOR COMPARTMENT BOX COMPARTMENT HAND THROW LEVER SELECTOR LEVER WHICH SLIDE BAR SWITCH M
25. Standard Base Complete Table 6 10 contains the parts list for the base used in the switch machines listed in Table 6 2 M 3 Table 6 3 M 23A and Table 6 4 M 23B Table 6 10 M 3 M 23A and M 23B Standard Base Complete Machine Arranged for Special Equipment Part Number Standard N291056 002 With Telephone Jack N291056 N294752 001 With Machined Mounting Lugs Bea TOV t60 M 23A M 23B To obtain service parts for machines with non standard bases specify the top level piece number of the machine 6 7 M 3 M 23A and M 23B Motor Assemblies Table 6 11 contains the parts list for the motor assemblies used in the switch machines listed in Table 6 2 M 3 Table 6 3 M 23A and Table 6 4 M 23B Figure 6 5 and shows a location diagram for the listed parts Table 6 11 M 3 M 23A and M 23B Motor Assemblies Description Part Number N422008 01 N451161 1701 N416007 01 Low Voltage Motor Assembly 20 VDC 442200802 N451161 1703 5 Motor Frame Adapter Not Required with J717245 0002 Motor M410006 02 High Voltage Motor Assembly 110 VDC Blue Motor Electric 110 VDC 189 1 and 360 1 Gear Ratio J717216 0301 Blue Motor Electric 20 VDC 360 1 and 528 1 Gear Ratio J717216 0302 Blue Motor Electric 20 VDC 528 1 Gear Ratio J717216 0303 Black Motor Electric 20 VDC 360 1 and 528 1 Gear Ratio J717216 0501 Black Motor Electric 20 VDC 189 1 and 36
26. and lower spring cups Now operate the hand throw lever toward Reverse The selector clutch should snap up into engagement with the hand throw pinion just before the hand throw lever is fully down in the Reverse lever stand Check that the hand throw lever will now operate the machine e With the hand throw lever in Reverse operate the machine by power to the Normal position Operate the selector lever to HAND The selector clutch should ride against but not engage the hand throw pinion tooth The selector clutch spring should be compressed taking up the clearance between the upper and lower spring cups Now operate the hand throw lever toward Normal The selector clutch should snap up into engagement with the hand throw pinion just before the hand throw lever is fully down in the Normal lever stand Check that the hand throw lever will now operate the machine 2 7 Electric Connections and Control Wiring In accordance with all applicable railroad safety and operating standards connect the external wiring to the terminal board in accordance with the wiring diagram for the particular location Figure 2 5 shows internal view A and control wiring views B and C for low voltage machines using five wire control which is intended primarily for permanent magnet motor replacement on existing installations Figure 2 6 shows internal view A and control wiring views B and C for low voltage machines using three wire control which is intended prima
27. controller terminal board at that end No additional holes are required and terminal space is available on the terminal board Refer to Figure 2 6A and Figure 2 7A for wiring arrangements The heater for the motor compartment is mounted on the motor assembly cradle as shown in Figure 3 17 SM 6263 Rev 7 June 2009 3 23 A Operation AnsaldoSTS HEATER Heater for Motor Compartment Gray Motor Applications Heater for Circuit Controller HEATER 15W 115 230 VOLTS HEATER 15W 115 VOLTS OR 15W 24 VOLTS HEATER Heater for Motor Compartment Blue Motor Application Figure 3 17 Heaters for Circuit Controller and Motor Compartments 3 24 SM 6263 Rev 7 June 2009 SN AnsaldoSTS Field Maintenance 4 FIELD MAINTENANCE WARNING Disable the motor control circuit before beginning any work on a switch machine If not electrical shock or personal injury may result NOTE The field maintenance procedures covered in the following paragraphs are those recommended by ASTS USA The field maintenance policy of the customer will depend on actual operating experience and capability 4 1 Preventive Maintenance The following preventive maintenance procedures are intended to detect possible causes of switch machine failure before an actual failure occurs Detection of such possible failures is accomplished by a scheduled maintenance process whereby the switch machine
28. each has a wide notch located alongside the narrow notch of the other As the notch is on top of the lock rods for one position of the switch and on the bottom for the other position and as the lock box likewise has one dog on top and the other on the bottom it follows that the slide bar with its lock box can complete its stroke only if the lock rods are shifted by the switch points to the position corresponding to proper point closure When the stroke is completed the switch of course is secured by the locking The stroke of the slide bar and its lock box is such that the locking dogs provide adequate interlock with only the lock rod that the dog enters first Therefore the lock box and the lock rods must be so assembled that the dogs will enter the narrow notches first Procedure for inverting the lock box when necessary is given in paragraph 2 11 1 3 3 Circuit Controller The circuit controller has indication contacts that are operated jointly by the lock box and the point detector mechanism The contacts are operated in such a manner that the machine as checked by the lock box must have completed its throwing and locking stroke in the proper direction and the corresponding switch point must be closed properly as checked by the point detector before the corresponding indication contacts can close It also has segmental type motor control contacts for opening the motor circuit when the machine is in its full normal or full reverse positio
29. gearing in accordance with the information given under Train in Section 3 5 The high or low voltage motor may be replaced by the low or high voltage motor by making the required wiring changes Figure 2 5 and Figure 2 6 show low voltage wiring and Figure 2 7 and Figure 2 8 show high voltage wiring 2 11 4 Converting Between Five and Three Wire Control Conversion of switch machine between five and three wire control may be performed in the field by rearranging jumper lead connections on the terminal board Additional leads necessary for the conversion are supplied with all switch machines in a bag attached to the terminal board Before any conversion is performed identify the type of control currently used High voltage three wire control may be identified by the presence of a jumper from terminals A to B or A to C Low voltage three wire control may be identified by a jumper from terminal 34 to C or 34 to B Five wire control may be identified by the absence of the these jumper connections See Figure 2 5 through Figure 2 8 view A for the location of these jumpers Perform one of the following sequences to accomplish the conversion e Five to Three Wire Control 110 VDC 1 Remove lead D to A 2 Addlead D to 5 3 Add lead 10 to 35 4 For left hand operation add lead A to C 5 For right hand operation add lead A to B e Three to Five Wire Control 110 VDC 1 For left hand operation remove lead A to C
30. lt L w 1000 Technology Drive Pittsburgh PA 15219 AnsaldoSTS Se 29006 SM 6263 M 3 M 23A M 23B Electric Switch Machines with Permanent Magnet Motor ASTS USA Part No N451160 xxxx N416001 xx N416002 xx nstallation Operation Troubleshooting Copyright 2009 SM 6263 Rev 7 Ansaldo STS USA Inc June 2009 N 77 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
31. no major differences between these machines and M 3 M 23A and M 23B machines with field wound motors The difference is the motor itself and the wiring associated with it For permanent magnet motor replacement on existing installations the machine can be wired for five 5 wire control On new installations the machine is wired for three 3 wire and two 2 wire control This is covered in more detail in later sections of this manual For ALSTOM GRS replacement machines the switch machine is wired for two 2 wire control See Section 7 NOTE For information on the Electronic Circuit Controller upgrade for the M 3 M 23A and M 23B machines refer to service Manual SM 6263A 1 2 Description The M 3 M 23A and M 23B machines consist essentially of a motor a gear train cam arrangement for operating the switch and the locking and circuit controller that includes a point detector with latchout device They all use the same base casting and are interchangeable as to mounting and connections in a switch layout except the additional height of the M 23A and M 23B machines compared to the M 3 machine may affect clearance see dimensions in Figure 2 3 and Figure 2 4 Typical applications are shown in Figure 1 1 and Figure 1 2 The M 3 machine has no facilities for hand operation except that in an emergency it may be operated by inserting a removable crank The M 23A and M 23B machines have dual control features that includ
32. strip No adjustment should be necessary to obtain these dimensions if spring M is made properly e With contacts at indicating position check gap clearances at Y for 3 64 inch to 5 64 inch and check contact pressure between indication contact spring M and fixed contact with spring scale at X to see if pressure is 1 1 2 pounds to 2 1 4 pounds Adjust reinforcing spring breakaway load if necessary to meet these requirements and recheck to make sure it is not greater than 11 pounds or less than 8 pounds 5 12 SM 6263 Rev 7 June 2009 5 7 AnsaldoSTS Shop Maintenance With contacts made against short circuiting strip check at front end of contact fingers with push scale for a load of 1 1 2 pounds to 4 pounds 5 5 7 Assembly Lever Interlock The sectional views in Figure 2 9 illustrate the lever interlock assembly It comprises recesses in both lever hubs and a steel ball carried in a hole in the lever support In reassembling BE CAREFUL TO NOT LOSE THE BALL when the lever is taken off As can be seen in the diagrams the diameter of the ball is greater than the thickness of the wall of the lever support Thus with the selector lever in the MOTOR position as shown part of the ball is held in the recess of the hand throw lever and thereby prevents operation of the hand throw lever Reversing the selector lever aligns the ball recess in its hub to permit the ball to shift out of the recess in the hand throw lever hub thereb
33. the gearbox wall when the hasp is fully compressed See Figure 5 6 Section Z Z d Ifthe hasp does not engage the notch in the staple loosen the jam nut on the push rod A and tighten the push rod A so that the hasp engages the notch with a maximum gap of 1 32 between the hasp and staple notch e Tighten the jam nut SM 6263 Rev 7 June 2009 5 21 em lt Shop Maintenance AnsaldoSTS O m Lam al MIL lt Tam B APPROX B j m 0 ni E zu M DETAIL A X wg LATCH RELEASE G Figure 5 7 Machine in Hand Operation Covers Open 1 16 TO 1 8 NOTE ENSURE HAND CRANK CANNOT BE INSERTED Figure 5 8 Machine in Motor Operation Covers Closed 5 22 SM 6263 Rev 7 June 2009 EN AnsaldoSTS Shop Maintenance IMPORTANT INSPECTION REQUIRMENTS a With the gearbox cover installed and the crank cover open verify that the motor cutout contacts are dependably open with the crank installed b Precise measurem
34. the wear plates supporting the operating bar must be removed first allowing the operating bar and crank roller to drop down Then rotate crank turn friction clutch by hand until bottom end is crosswise of machine Unscrewing the nut at the top of the main crank shaft will then permit the crank to drop out through the bottom Removal of the main crank will release the worm gear and the slide bar 5 4 7 Removal of Selector Clutch For dual control machines M 23A and M 23B removal of the selector clutch and associated parts can readily be understood from the information given for changing from R H to L H assembly or vice versa However when reassembling the selector clutch note that all its overall height including top and bottom teeth is 5 9 32 inches max to 5 17 4 inches min This dimension is adjustable by turning the top and bottom parts of the clutch assembly with respect to each other This can best be done by inverting and placing hand portion on the crank splines and turning motor portion with screw driver or bar in motor clutch teeth Splines in both parts must be aligned to permit reassembly For timing of the dual control gearing upon reassembly see Section 5 5 2 5 4 8 Removal of Worm Shaft To remove the worm shaft it is necessary to take the gearbox off the base casting otherwise the end of the shaft would strike the wall of the circuit controller compartment 5 4 SM 6263 Rev 7 June 2009 5
35. to slip at 23 amps for field applications if desired CLUTCH HOUSING CLUTCH SPRING LT 1 ZN i N 284 UN TA gt KSS SS IANA EII ZI ASE E VU IUJ NIE 212 252 ADJUSTING NUT OIL SEAL CLUTCH PLATE FABRIC DISC 1 3 8 ir 159 HOLE 21 DRILL SIZE PINS PRESSED IN SOCKET FOR Ti1 6 11 16 LEVER ROD 1 PIPE 1 5 8 DIAM 1 5 16 DIAM PC 173641 TEMPORARY TOOL MAY BE MADE BY FILING PENS ON THE END OF A PIECE OF 1 PIPE AS SHOWN Figure 5 2 Friction Clutch Assembly and Special Wrench for Packing Gland Nut 5 10 SM 6263 Rev 7 June 2009 5 4 AnsaldoSTS Shop Maintenance 5 5 6 Reinstallation of New or Rebuilt Circuit Controller NOTE It is necessary that the lock box be toward the motor end before installing a new or rebuilt controller into the switch movement This is done by operating the movement to the end of its stroke using the hand crank M 3 or hand throw lever M 23A M 23B Refer to Figure 6 1 and Figure 6 2 Using the hand crank M 3 or hand throw lever M 23A or M 23B operate the movement to the end of its stroke This places the slide bar and lock box toward the motor Lower circuit controller into circuit controller compartment Align mounting holes Reinstall the two screws 8 and 3 8 lock washers in the holes nearest the motor compartment Reinstall the plate 9 two 1 2 13 x 1 hex head cap screws 6 and two 1 2 lock washer
36. will collect in a recess and be led to shaft surfaces needing lubrication b Linkage connections for motor cutout 4 M 3 M 23A and M 23B machines fill recess on top crank bearing Apply a light oil ASTS USA Spec M 7610 02 1 To contact segments of indication circuit controller segments and contact springs should be thoroughly cleaned before application 2 Sparingly to motor commutator 1f brushes chatter d From the container shipped with the machine apply the gear lubricant Spec M 7652 3 5 16 This is a low temperature all weather lubricant that has little change in consistency with temperature variations It will retain its lubricating properties at the highest temperatures encountered and not become so stiff at low operating temperatures as to require thinning If sustained abnormally low temperatures are anticipated a special lubricant may be ordered Contact your salesman or the Engineering Department for an ordering reference number M 3 M 23A and M 23B machines Apply a light coat of gear lubricant to spur gear teeth The gear lubricant must be packed well around the worm gear and the selector clutch in the worm gear compartment It must be replaced as necessary to keep the worm gear covered CAUTION Lubrication at proper intervals is essential to ensure proper equipment operation Do Not Permit Grease Or Oil To Enter Spring End Of Friction Clutch Otherwise Friction Clutch May Malfunction
37. 0 1 Gear Ratio J717216 0502 Gray Motor Electric 20 VDC 360 1 and 528 1 Gear Ratios J717245 0002 Screw 3 8 16 x 1 Hex Socket Head Not Required with J717245 0002 J500124 0002 Motor SM 6263 Rev 7 June 2009 6 27 5 Configuration Guide and Parts List AnsaldoSTS Description Part Number M451161 1601 Key 3 16 Square Steel M451161 1305 Screw 10 32 x 1 4 Allen Head J507363 Snap Ring Ext Retaining J792852 Washer 17 64 x 9 16 Copper Not Required with J717216 0301 J047818 Motors Washer 5 16 Ext Cnsk Lock Not Required with J717216 0301 J475143 0001 Motors Washer 3 8 Ext Cnsk Lock Not Required for J717245 0002 Motor _ J475143 0002 Table 6 12 M 3 M 23A and M 23B Motor Brushes Motor Part Brush Kit Spring Kit 041000601 IT Y jx CX 3 Figure 6 6 M 3 M 23A and M 23B Blue Motor Assembly 6 28 SM 6263 Rev 7 June 2009 A AnsaldoSTS Configuration Guide and Parts List Figure 6 7 M 3 M 23A and M 23B Black Motor Assembly SM 6263 Rev 7 June 2009 6 29 N 3 Configuration Guide and Parts List AnsaldoSTS 1 4 20 UNC BRASS Figure 6 8 M 3 M 23A and M 23B Gray Motor Assembly 6 30 SM 6263 Rev 7 June 2009 A Z AnsaldoSTS Two Wire Control for ALSTOM GRS Repl
38. 02 LA SH3dWnr 6 JOVId V TIOHLNOO SYHIM 2 T3103NNOO SI H3HLO HOIHM OL IVNINHAL JO SMOHS 310410 NI LON HASAN UVO TWNINYAL JO NOLIVNOIS3Q S1NASAUdAU 31080 NI HJSWNN L J SSINYYH NIVIA Sv p n j 700 085962 NOLIVLOH 1X3N v 4 09 30 NOllOadlq HalvaH Sf C LNAIHVJINOO p ONILSVO 3SV8 30 dOL LE HOLOMW Nie 191 WALI 091 WALI sarawassv a E roa 22 O dO 9NDIOVIS 9NIMOHS MAIA w Uu SO1O313S 8 Quvoa Q3TIOH1INOO SIOVINOS NIVIN p06S 1911GPN o o HO c06S L9LLGEN aasn NaH 4 0 S3NuvH x Q l WALI 091 WALI 531181359 3aola HOJ SNOILVNOSIS3Q HOLO3NNOO TWNIWHAL ONIMOHS MAIA SM3UOS ONILNNOW H3TIOHINOO LINDHIO HJONN NMOHS NOILISOd NI G3 18A3SSV 38 OL ovr 3NOHd 50060 SdNVTO SS3NuvH v 1090 78 45 uo ze S0OHS r8 1Sr8 IVNINGAL 9 HOG OL LDANNODJ JYNINY 3L OLLO3NNOO 6c HO 82 i 66056 soc sem OL LOJNNOO fel seem a Jp kel eem v 5s HOLOVINOO Hs 908 NOLLOSNNOO NOLLOJNNOO om avaj 10 61002v9 7 5 Figure 7 3 Two Wire Control Schematic SM 6263 Rev 7 June 2009 5 3 Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS
39. 1 Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS SN AnsaldoSTS 7 14 SM 6263 Rev 7 June 2009 n AnsaldoSTS RAIL Team and Technical Support 8 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 Cansaldo sts us SM 6263 Rev 7 June 2009 8 1 N 3 RAIL Team and Technical Support AnsaldoSTS A AnsaldoSTS End of Manual 8 2 SM 6263 Rev 7 June 2009
40. 10011 01 Parts 7 10 Contactor Assembly N410011 01 X and Y Label Location 7 11 Motor Assembly N451161 1706 Parts 7 13 SM 6263 Rev 7 June 2009 vii A Table of Contents AnsaldoSTS Table 1 1 Table 1 2 Table 1 3 Table 3 1 Table 4 1 Table 5 1 Table 5 2 Table 5 3 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table 6 8 Table 6 9 Table 6 10 Table 6 11 Table 6 12 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 viii List of Tables Physical Characteristl65 sm A SAO GA VO 1 3 Operating Characteristics aaa 1 3 Electrical Data uu Sta ia a eee an ees ee a i edu 1 3 Gear Ratio Reduction Gear 3 15 Preventive Maintenance Schedule sse 4 1 Maintenance Tools eate S Da S ak a etn ete yuk aaa ikto 5 1 Adjustment to Slip the Clutch n u 5 10 Lubrication Specifications for M 3 M 23A M 23B Switch Machines 5 17 M 3 M 23A and M 23B Configuration 6 1 M 3 Switch Machine Assemblies 22 2 4 1 eene nennen 6 2 M 23A Switch Machine Assemblies ss
41. 2 by 1 32 1 64 min When contacts are closed as shown in Sect W W and X X and to permit finger F1 to clear finger F2 by 1 16 minimum when contacts are open as shown in Sect Y Y and Z Z Adjust finger F3 to bear on the segment with 1 3 4 to 2 Ibs pressure 5 5 6 2 Contact Pressures and Clearances Contact pressures and clearances must be in accordance with Sections P P and N N of Figure 3 7 and are to be obtained by the following procedure a With switch machine at end of stroke to enable roller to drop into cam notch adjust reinforcing spring N by relieving tension with a spring bender to break away from the contact spring at a load of 8 to 11 pounds b Check clearance between cam and roller with roller in cam notch to see if it is 3 64 inch to 5 64 inch If not readjust reinforcing spring to obtain correct clearance and recheck reinforcing spring breakaway load to make sure it is not greater than 11 pounds or less than 8 pounds c Check that slotted ends of contact springs M are in alignment bear evenly on fixed contact W and on short circuiting strip and both contact springs of each pair make and break at the same time It may be necessary to slightly bend the contact fingers to meet this requirement d Check 1 8 inch minimum dimension between end of indication contact spring M and short circuiting strip Check 3 64 inch minimum clearances between spring M and fixed contact and between spring M and short circuiting
42. 23A and M 23B Configuration Guide Reference Description 15W 230V heater N285999 for circuit controller compartment 15W 230V heater N344344 for motor compartment 15W 115V heater N253225 for circuit controller compartment 15W 115V Heater N294241 for motor compartment 15W 115 230V heater N438201 for circuit controller compartment 15W 115 230V heater N294241 amp N296578 001 for motor compartment 001 15W 115 230V heater N296577 amp N296578 001 for motor 15W 24V heater N438179 for circuit controller compartment E P M 3 P M 23B New switch machines standardized after Feb 1 2004 to reflect three wire control hand crank cover is open R M3 M23A R S M3 LH switch machine set up for RH indication or RH switch machine set up for LH indication S M23A Telephone jack in circuit controller compartment T M 3 15W 115V heater N296580 004 for motor compartment M 23A With heater thermostat in motor compartment U M3 With telephone jack in circuit controller compartment V M3 For LH switch machine set up for RH indication machine is stenciled LH Far Pt CI For RH switch machine set up for LH indication machine is stenciled RH Far Pt CI V M23A W M3 W M23A Short circuiting strip shunt bar M175725 installed X M3 Y M 3 i indi Y i i Circuit controller arranged for manual reset of indication contacts M23A Circuit controller wi
43. 3 Controllers N284679 6 24 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List Item Description Part Number 59 Screw 5 16 18 x 5 8 Flat Head J052362 Washer 61 Wire Soft Black Iron W 18 62 Screw 5 167 18 Hex Head 63 _ Washer 5 16 Steel Extra Lock 64 Washer 1 4 Plate Steel Lock 65 Washer 3 8 SST Lock Cotter Pin 1 16 x 1 2 SST KKT 67 Cotter Pin 3 32 x 1 SST Cotter Pin 1 8 x 1 2 SST Fitting Hyd 90 degree Ell 1 8 NPT 70 Retaining Ring 71 Fiber Washer 72 Nut 14 24 Hex Brass 73 Shim 0 016 74 Shim 0 026 75 Nut 1 2 20 Thick Slotted 76 Washer 5 16 Plate Steel Lock 77 Heater Complete 78 Screw 5 16 x 2 SST Fillister Head 79 Washer 5 16 SST Plate J475120 0113 Tie Bar Long 81 Tie Bar Short 82 Gear N285638 004 Controllers SM 6263 Rev 7 June 2009 6 25 A Configuration Guide and Parts List AnsaldoSTS 80 32 1 TI ERE oke I r Uc EE Ep Lafl 209 K LI 7 20 6 1 z 3 A S I S I ZZ 92 49 EN CCC BA SECTION B B Figure 6 5 Indication Circuit Controller Parts Location 6 26 SM 6263 Rev 7 June 2009 AND AnsaldoSTS Configuration Guide and Parts List 6 6 M 3 M 23A and M 23B
44. 3 and 5 5 5 d Circuit Controller Refer to Sections 5 5 5 and 5 5 6 4 6 SM 6263 Rev 7 June 2009 5 AnsaldoSTS Shop Maintenance 5 SHOP MAINTENANCE 5 1 Special Tools Maintenance tools for M 3 M 23A and M23B switch machines are listed in Table 5 1 Ordering reference for complete set of tools is X296406 001 Drawing 012764 0001 Table 5 1 Maintenance Tools Maintenance Tools for M 3 M 23A and M 23B Switch Machines 6 Screw driver slotted 10 Screw driver slotted 6 Slip joint pliers 12 oz Machinist hammer ball peen nsulated socket wrench 1 2 Adjustable Crescent wrench 10 Adjustable Crescent wrench Set hex Sockets Ratchet wrench 1 2 drive Extension bar 1 2 drive 10 long Special pin wrench for clutch housing packing gland Thin head flat wrench 1 5 32 opening Allen wrench 3 16 Hex Clutch assembly gauge hand motor clutch Basket Wrench 2 1 16 open end ASTS USA M322680 or box wrench ASTS USA J49124401 5 2 Cleaning Al major mechanical parts should be thoroughly cleaned to remove accumulation of dirt grease and grime Use only appropriate cleaning agents for the material being cleaned and follow manufacturer s recommendations for use CAUTION Electrical components such as the motor heaters wiring harness or circuit controller should never be immersed in cleaning solution otherwise damage to these parts will occur 5 3 Inspecti
45. 350 0351 N451160 1602 Gearbox Complete Suffixes 0301 0302 N287486 Suffixes 0303 0318 0322 0325 0328 0329 0340 0345 N287485 0350 0351 4005 4006 Suffixes 0319 0320 N287484 DC Motor Complete Suffixes 0301 0302 N451161 1703 Suffixes 0303 0320 0322 0329 0332 0337 0340 0345 N451161 1701 0350 0351 Suffixes 4001 4006 N422008 01 Circuit Controller Complete Suffixes 0301 0310 0313 0320 0322 0323 0328 0329 N285638 0340 0345 LE __ Suffixes 0311 0312 0326 0327 4001 4004 285638 0 _ Suffixes 0324 0325 0332 0337 0350 0351 4005 4006 4518170501__ Suffixes 0352 0353 N45 1817 0503 6 0 E 8 mem E LE x 8 Screw No 6 x 1 4 Round Head Plated 05607 J me 4 tS 10 Ii rr vai Slide Bar Includes Stud Ref 103 and Rollers Refs 104 105 SM 6263 Rev 7 June 2009 6 5 5 Configuration Guide and Parts List AnsaldoSTS KN Operating Bar Lug M146443 19 Operating Bar Lug MI for part numbers N451160 0514 0543 M146443001 0546 and 0547 only 6 6 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List 60 Bushing 129622 6 LockWasher 1487 62 Lubricating Fitting 1 8 P T Straight 10039137 65 Colar 7 6 MO74722 67 am ort 68 6
46. 4V Heater For Motor Compartment Blue Motor Not Shown 15W 115 230V N296577 amp N296578 001 129 130 131 Heater for Motor Compartment Gray Motor Not Shown 15W 115 230V N4515890101 Both part numbers are required to order the 15W 115 230V heater 6 14 SM 6263 Rev 7 June 2009 lt Configuration Guide and Parts List 77 AnsaldoSTS LON QOH M201 01238 qasino3 I YALALA LNIOd N3HM A N 90141535 7727722722 LON SI eet HOLOGLIG LNIOd NAHM ov A N 404 235 l i MON HL ge m va py 2 00 9 fu vL oL ponl pst 6 l ral 2518 15 E i MJYDS 4015 HLIM KIEWISSV 8 4201 U3A39 gz 2 01 Tu pe 0235 LA Ss fute ie 201 tor v Z Z NOI123S TADON iy L B 9 2O 80 voc oc usoj ve L L6 GHI 89 el 92 ye 4 v6 7 LE Figure 6 2 M 23A and M 23B Switch Machine Single Switch 6 15 SM 6263 Rev 7 June 2009 N 3 Configuration Guide and Parts List AnsaldoSTS 6 3 M 3 Switch Machine Gear Box Parts List Table 6 7 contains the parts list for the gear boxes used in the switch machines listed in Table 6 2 M 3 Figure 6 3 shows a location diagram for the listed parts Table 6 7 M 3 Gear Box Parts List Gear
47. 5 7 AnsaldoSTS Shop Maintenance When necessary to adjust the eccentric bushings check that top rollers are free from bearing on the upper spring cup while the selector clutch is fully down and in addition check that the rollers are not too high To do this operate the selector lever to MOTOR position when the worm gear is not in position to receive the selector clutch so that the teeth of clutch for motor operation Figure 3 14 ride on top of the corresponding teeth of the worm gear In doing this insert 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 their bolt tight when the selector lever is thrown to horizontal position for MOTOR operation the force between the opposed teeth will crush the wire to not more than 1 32 thickness Also check that upper rollers are free to turn when selector clutch is fully engaged with the worm gear SM 6263 Rev 7 June 2009 5 25 Shop Maintenance AnsaldoSTS 25 y AnsaldoSTS 5 26 SM 6263 Rev 7 June 2009 EN AnsaldoSTS Configuration Guide and Parts List 6 CONFIGURATION GUIDE AND PARTS LIST Table 6 1 lists the available configuration options for the switch machines covered by this manual Refer to Table 6 2 M 3 Table 6 3 M 23A and Table 6 4 M 23B for the actual configuration options that apply to specific switch machines Table 6 1 M 3 M
48. 6 69 Ii ir _ 4 j 70 NotUsed S ZI ir J048010 GE Tom 2 73a 74 Bolt J050088 75 J050090 76 J050092 77 1522151 78 3066012 79 M308325 J039142 81 J050044 J052091 M399589 Lock Washer J047821 Lubricating Fitting 1 8 P T J039137 Burndy Cable Clamp HP 24N J700589 82 83 84 4032902 85 87 8 242439 8 Long Closed Lock Rod Cover To be used with Lock Rods having adjustment on field side similar to AREMA Drawing 1587 J050048 89a J047768 M287186 91 074735 92 074736 93 074738 94 95 97 242441 285692 272961 285680 301050 98 Pn 209199 J049475 100 J049452 101 M115706 102 029101 SM 6263 Rev 7 June 2009 6 13 5 E Configuration Guide and Parts List AnsaldoSTS Description Part Number Washer Nut Tag Orders should specify marking desired Not shown Not Used zi Not Used Not Used Not Used Eu E Not Used Screw No 12 28 x 1 1 8 Rd Hd S Plated w Nut Ref 111a Nut Washer Cover Plate Ventilator Nut 5 1618 UNC Washer 5 16 Steel Lock Plated Washer 3 8 Steel Lock Washer 1 2 Steel Lock Nut 3 8 Hex Jam Washer 5 16 Steel Plated Nut 5 16 18 UNC Screw 5 16 x 1 2 Hex Hd Washer 5 16 Steel Lock Washer Washer 10 Steel Lock Med Washer 10 Fil Steel Heater For Circuit Controller Not Shown 15W 115V 15W 230V 15W 115V 15W 2
49. 65762 Screw J052202 Screw 10 32 x 9 16 Steel J522151 Harness Clamp J700589 Hand Crank M146694 Washer Lock J047521 Washer 1 2 Steel J047769 Washer 3 8 Steel Lock J047768 Nut 3 87 16 UNC J048010 Washer 5 16 Plated Steel Lock J047526 Washer M002423 Screw 5 16 x 1 2 Hex Rd J050034 Washer 5 16 Steel Lock Ex J047767 Screw 1 2 x 1 1 2 Socket Head J050236 Washer 5 16 Steel Plated J047642 Heater for Circuit Controller Compartment Not Shown egit 15W 115V N253225 15W 230V N285999 15W 115 230V N438201 15W 24V N438179 Heater for Motor Compartment Not Shown 15W 230V N344344 15W 115V N294241 15W 115 230V N296577 amp N296578 0001 15W 24V N438178 Both part numbers are required to order the 15W 115 230V heater 6 8 SM 6263 Rev 7 June 2009 lt N Configuration Guide and Parts List 77 AnsaldoSTS 2 4 LI W Hil GZJUMVIU SI YOL 23 30 LNIOd N3HM X X NOILO3S 7232777274 PKK 6S Ap en E 92 ve co 09 LON SI Y207 N3HM NOLO3S cet NOILD3S TT TOU GOL OL 900 NOIL23sS PL 7 9r eL as 098 90 vo OF v L e 98 021 Ev Zr e Figure 6 1 M 3 Switch Machine Single Switch Parts Location 6 9 SM 6263 Rev 7 June 2009 5 E Configuration Guide and Parts List AnsaldoSTS 6 2 M 23A a
50. 9 Washer 7A 70 Cotter Pin 1 8 x 3 4 104868 71 GearboxCover 5263 572 738 75 75a os 79 81 Screw 1 2 13x1 Steel 05008 e 82 Screw 1 2 13 x 1 1 4 Hex 050090 84 jOotterpn i 04866 85 j PipePug L 403290 86 Lubricating Fitting 1 8 P T 671 20 01 J039142 4 87 Screw 5 16 18x1 3 4 Steel 050045 O 88 Screw 10 32 x 1 2 FI Rd 1 405209 89 PipePug PP 6 J03200 Ra Long Closed Lock Rod Cover To be used with lock rods having adjustment on field side similar to A A R drawing 1587 91 CovePlte M9Z9 0 92 NotUsd NotApplicabe 93 Stud M743 O 94 Stud 07438 95 jLockRodSupot 1 1 L LaMo7478 O 96 Hingelug 2856 97 jAdistabeHasp _ 2729 98 Eccentric Stud 42 6 4 M285680 99 Sud 4 Mi4734 61 62 65 67 70 71 72 73 74 75 75a 76 77 78 79 81 82 84 85 87 88 91 92 93 94 95 97 SM 6263 Rev 7 June 2009 6 7 5 E Configuration Guide and Parts List AnsaldoSTS Nut J480300 Gasket 5 2 long A067035 Gasket Orders should specify length desired M320440 M146671 M146674 Crank M146673 Screw Jaw M146677 Spring 074790 0
51. AIN SHIFTS SELECTOR CLUTCH OPERATING CRANK ALONG SPLINES ON MAIN BAR CRANK SHAFT SEE NOTE A LOCK BOX THROW LEVER WHICH ROTATES HAND THROW PINION DETECTOR ROD WIRE y OUTLET LOCKING DOGS CIRCUIT CONTROLLER 1 OPERATED BY THESE RACK TEETH INDICATION CONTACTS ARE AFFECTED ALSO BY POINT MAIN CRANK ROLLER DETECTOR NOTE CLUTCH OVERALL HEIGHT IS SUCH THAT TOP TOOTH MUST ENGAGE HAND THROW GEAR BEFORE BOTTOM TEETH CAN DISENGAGE WORM GEAR OR VICE VERSA THUS THE MAIN CRANK IS NEVER FLOATING BUT AT ALL TIMES IS ENGAGED WITH EITHER THE MOTOR OR THE HAND THROW LEVER 62 0010 00 Figure 1 2 M 23A and M 23B Switch Machine Outline Diagram SM 6263 Rev 7 June 2009 1 5 AV General Information AnsaldoSTS A AnsaldoSTS 1 6 SM 6263 Rev 7 June 2009 5 7 AnsaldoSTS Installation and Adjustments 2 INSTALLATION AND ADJUSTMENTS 2 1 General Information In general the application of the M 3 M 23A and M 23B machines is as shown in Figure 2 1 and Figure 2 2 but detail mounting plans approved by the railroad should be followed when installing the machine Mounting dimensions are shown in Figure 2 3 and Figure 2 4 Switch machines are assembled at the factory to suit particular layouts when sufficient information is provided in the order but can be changed from right hand to left hand or vice versa in the field Conversion of the M 3 is very simple and no detail instructio
52. Dual Control M 23A and M 23B RH to LH LH to RH 5 5 5 5 3 Reinstallation of Motor Brushes n nnn nnn inna nana nana 5 7 5 5 4 ReinstallationsOf Motor nis oe eL eee Deere gie eee eee vxo Tee e da ent ege 5 8 5 5 5 Reinstallation of Friction Clutch 5 8 5 5 6 Reinstallation of New or Rebuilt Circuit Controller 5 11 5 5 7 Assembly Lever InterlocK ertet 5 13 5 6 ii d i e 5 14 57 cAGJUSIMENIS amens 5 17 S Z lp Polnb Detector q estr voe Pee ede TET 5 17 5 7 2 Motor Cutout Contacts ma TO E 5 18 5 7 3 Selector Clutch Adjustment nennen tenens 5 24 iv SM 6263 Rev 7 June 2009 AT 77 AnsaldoSTS Table of Contents 6 CONFIGURATION GUIDE AND PARTS LIST 2222222 2 1 6 1 6 1 M 3 Switch Machine Single Switch Parts 6 5 6 2 M 23A M 23B Switch Machine Single Switch Parts 6 10 6 3 M 3 Switch Machine Gear Box Paris 6 16 6 4 M 23A and M 23B Switch Machine Gear Box Parts 6 19 6 5 M 3 M 23A and M 23B Indication Circuit Controllers
53. ET TO Oo T BOLTS G SIDE VIEW Figure 3 5 Indication Circuit Controller The shaft assembly Figure 3 7 consists of a square shaft on which the two end insulating washers the four motor control segment insulating bushings the two eccentric bushings and the gear each have square holes to force them to rotate with the shaft To ensure proper relative assembly of the gear and eccentric bushings the shaft is made with unlike ends so that it can go into the controller only one way The shaft has one corner flattened for a distance of 2 at one end and 3 at the other end and the gear and the eccentric bushings have dowel pins that can be assembled only in these flats With the exception of the indication cams and their coil springs the two arms of the yoke and the operating levers all the parts are pulled up solidly end to end by the nuts on the ends of the shaft The indication cams and their respective springs ride on the gear hub and are held against the gear face by action of the springs and locked in place with set screws The cams may have either of two operating positions as determined by slots in the cam hub engaging the stud in the gear face The yoke is free to rotate around the concentric hub SM 6263 Rev 7 June 2009 3 7 N Operation 77 AnsaldoSTS portions of the eccentric bushings and the operating levers are free to rotate around the eccentric portions or be held stationary while the shaft and eccentric bushings rot
54. IN TERMINAL BOARD Figure 2 6 M 3 M 23 Low Voltage DC Machines Three 3 Wire Control SM 6263 Rev 7 June 2009 2 9 A Installation and Adjustments AnsaldoSTS A INTERNAL WIRING CIRCUIT CONTROLLER CIRCUIT CONTROLLER MAIN TERMINAL BOARD I CONTACTS CONTROLLED SELECTOR LEVER A A SHUNTING STRIP G0 9 30 8 12 GD DIRECTION OF 3 NEXT ROTATION NOTE NUMBER CIRCLE REPRESENTS NUMBER OF TERMINAL NUMBER NOT IN CIRCLE SHOWS NUMBER OF TERMINAL TO WHICH OTHER END OF WIRE IS CONNECTED CONTROL WIRING To Control A A Circuit PP 151 T Tun Relay To N WR Control Circuit PN 150BM SWITCH MACHINE MAIN TERMINA BOARD SWITCH MACHINE MAIN TERMINAL BOARD POLAR NEUTRAL B C NOTE EXTERNAL CONNECTIONS ARE SHOWN TO THE MAIN TERMINAL BOARD FOR A SWITCH HAVING THE RIGHT HAND POINT NORMALLY CLOSED FOR A SWITCH HAVING THE LEFT HAND POINT NORMALLY CLOSED INTERCHANGE THE EXTERNAL LEADS TO TERMINALS B AND C AND TO TERMINALS 5 AND 10 ON THE MAIN TERMINAL BOARD Figure 2 7 M 3 M 23 High Voltage DC Machines Five 5 Wire Control 2 10 SM 6263 Rev 7 June 2009 5 77 AnsaldoSTS Installation and Adjustments A INTERNAL WIRING c CIRCUIT CONTROLLER bel CONTROLLER MAIN TERMINAL BOARD ED 3 37 CONTACTS CONTROLLED BY SELECTOR LEVER E SHUNTING STRIP Go a 52 30 49 12 6 DIRECTION OF 3 NEXT ROTAT
55. ING PIN POINT DETECTOR BAR om CAM ON YOKE CONNECTING RODS SHAFT GEAR INDICATION CAMS E YOKE k TO OPERATINO 8 lo CIRCUIT CONTROLLER SHAFT CRANK a OPERATING LEVER r7 YOKE STOP NTR I CRANK SPRING ECCENTRIC BUSHING YOKE POINT DETECTOR CONNECTING ROD gt ROLLER OPERATING PIN Figure 3 10 Schematic Diagram of Point Detector Parts in Reverse Position POINT DETECTOR ROLLER CRANK SPRING CRANK LI OPERATING LEVER 27 41 WE CONNECTING ROD P LA CIRCUIT CONTROBLER SHAFT LATCH LATCH SPRING E POINT DETECTOR BAR SHAFT GEAR sss cm h e CONNECTING RODS puni SDN YOKE TA i ab m I INDICATION CAMS i iss 4 1 i gt Tl pe cm ea cute operating i FE PIN NO EE Ii CRANK Tinte OPERATING LEVER SPE 2 CRANK SPRING ECCENTRIC BUSHING POINT OETECTOR CONNECTING ROD OPERATING PIN ROLLER A Figure 3 11 Schematic Diagram of Point Detector Parts in Reverse Position and Latched Up With the switch machine in the normal position as shown in Figure 3 8 point detector rollers A and B stand clear of the point detector bar thus preventing wear of point detector parts under SM 6263 Rev 7 June 2009 3 13 N Operation 77 AnsaldoSTS traffic conditions Roller A however is in position to deflect the yoke
56. ION NOTE NUMBER IN CIRCLE REPRESENTS NUMBER OF TERMINAL NUMBER NOT IN CIRCLE SHOWS NUMBER OF TERMINAL TO WHICH OTHER END OF WIRE IS CONNECTED CONTROL WIRING To Control Circuit To Control Circuit PN 150BM Relays PN 150BM Relay SWITCH MACHINE MAIN TERMINAL BOARD POLAR NEUTRAL B C NOTE EXTERNAL CONNECTIONS ARE SHOWN TO THE MAIN TERMINAL BOARD FOR A SWITCH HAVING THE RIGHT HAND POINT NORMALLY CLOSED FOR A SWITCH HAVING THE LEFT HAND POINT NORMALLY CLOSED INTERCHANGE THE EXTERNAL LEADS TO TERMINALS 35 AND D AND TO TERMINALS B AND C ON THE MAIN TERMINAL BOARD Figure 2 8 M 3 M 23 High Voltage DC Machines Three 3 Wire Control SM 6263 Rev 7 June 2009 I 3 Installation and Adjustments AnsaldoSTS The current style of plug in switch control relay is the PP 151 used in conjunction with the PN 150BM relay This is the equivalent of the shelf type DP 25 or the earlier style plug in type PNP 69 The PP 151 is a magnetic stick relay used for reversing the polarity of the switch motor and keeping the operating winding and stick winding of the overload relay in agreement The PN 150BM is a biased relay with magnetic heavy duty contacts and is used for closing the switch motor circuit and opening it under abnormal conditions These two relays in combination are also self checking because of the bias feature on the PN 150BM relay Figure 2 5 through Figure 2 8 view B are typical sw
57. M 23A and M 23B Switch Machine Outline Diagram seen 1 5 Typical Machine Application nennen 2 2 Typical M 23A and M 23B Machine Application 2 3 Typical Mounting 2 4 Typical M 23A and M 23B Mounting enne 2 5 M 3 M 23 Low Voltage DC Machines Five 5 Wire Control 2 8 M 3 M 23 Low Voltage DC Machines Three 3 Wire Control 2 9 M 3 M 23 High Voltage DC Machines Five 5 Wire Control 2 10 M 3 M 23 High Voltage DC Machines Three 3 Wire Control 2 11 M 23 Switch Machine Standard Lever Interlock 2 14 Schematic Diagram of Switch Operating 3 2 Diagram of Driving Parts Sheet 1 of 2 eee 3 3 Diagram of Driving Parts Sheet 2 2 3 4 Adjustable Lock Rods for R H and L H Operation 3 6 Indication Circuit Controller I nnne 3 7 Sectional View of Indication Circuit Controller a 3 8 Circuit Controller Adjustment and Shaft Assembly Diagram 3 9 Schematic Diagram of Point Detector Parts in Normal Position
58. NSHIPS REMAIN THE SAME LOCK RODS CLOSE CLEARANCE LOCK ROD ASSEMBLY SHOWN Figure 3 2 Diagram of Driving Parts Sheet 1 of 2 SM 6263 Rev 7 June 2009 3 3 N Operation 77 AnsaldoSTS A INITIAL POSITION x i MID POSITION OPPOSITE POSITION Figure 3 3 Diagram of Driving Parts Sheet 2 of 2 3 4 SM 6263 Rev 7 June 2009 V 77 AnsaldoSTS Operation The lock box rests on and is operated from an extension of the slide bar as shown in Figure 3 2 and Figure 3 3 During the first 40 degrees of rotation of the main crank the corresponding motion of the slide bar withdraws the lower locking dog of the lock box from the lower notch of the lock rod thus unlocking the switch points The following 140 degrees of rotation of the crank operates the switch and the lock rod stops with its upper notch aligned to receive the upper locking dog of the lock box The final 40 degrees of rotation of the crank completes the stroke of the slide bar driving the upper locking dog into the lock rod notch to lock the switch points in the reverse position 3 2 Switch Point Locking The lock rods in Figure 3 4 are comprised of two rectangular rods side by side Each has a narrow notch only slightly wider than the locking dogs this narrow notch in one rod being on top and in the other rod on the bottom To allow for variations in switch throw the two rods are adjustable longitudinally with respect to each other and
59. S 67 VIEW OF 189 TO 1 GEAR RATIO ASSEMBLY ER 5 CI Z pem mi DR E Odi za SULO Ne Va NM SUR 2 im VA PAS 4 gt zi I mA IET 84 Figure 6 4 M 23A and M 23B Gear Box Parts Location 6 22 SM 6263 Rev 7 June 2009 AnsaldoSTS Configuration Guide and Parts List 6 5 M 3 M 23A and M 23B Indication Circuit Controllers Table 6 9 contains the parts list for the circuit controllers used in the switch machines listed in Table 6 2 M 3 Table 6 3 M 23A and Table 6 4 M 23B Figure 6 5 shows a location diagram for the listed parts Table 6 9 M 3 M 23A and M 23B Indication Circuit Controllers Description Part Number N285638 Circuit Controller with Selective Point Detector Idler Bearing Pinion 1 9 16 Steel Round Pin 3 8 Steel Round Bracket Yoke Complete Bushing 0 3755 ID x 0 564 OD Bushing Oil Impregnated L H Crank 5 Roller 7 8 Steel Round M284423 Roller Pin M284851 R H Crank Roller 7 8 Steel Round Foller Pin Connecting Rod Lever Operating Component Rod Connecting Pin 1 4 Steel Round Latch Eccentric Bushing Bushing Eccentric Roll Pin Elastic Stop 1 8 x 1 2 SM 6263 Rev 7 June 2009 6 23 5 Configuration Guide and Parts List AnsaldoSTS Description Part Number Terminal Connector N146478 Gear 001 and 00
60. Z in Figure 5 6 with linkage positioned as if the hand crank cover were closed l 2 10 11 If there is a gap between yoke B and bearing inspect spring on eyebolt L If spring is completely compressed solid loosen nuts until spring is not solid and tighten nuts N Rough dimensions are 1 7 8 See Figure 5 7 If there is still a gap between yoke B and bearing C inspect screw jaw D to verify it is not striking the bearing frame noted in top view of Figure 5 6 If screw jaw strikes the bearing frame loosen nut M and remove the screw in eyebolt L Tighten eyebolt one half turn install screw through eyebolt and tighten nut M Verify yoke B rests against bearing C in both hand crank hasp open and closed positions Re adjust if necessary After verifying the above conditions manually position the yoke B in the hand crank hasp closed position by pressing the push rod A inward With latch release lever G released check the gap in Detail A of Figure 5 7 If the gap 1 not within the specified range of 1 16 to 1 8 loosen the jam nut on push rod F and remove the bolt through screw jaw D To increase the gap tighten the screw jaw To decrease the gap loosen the screw jaw Adjust as needed and tighten jam nuts c Secure the gearbox cover and close the hand crank cover hasp The hasp must engage the notch in the staple on the gearbox wall but should not contact
61. a gt x N Li md 1 3 Li 41 3 E z ph enim gt 5 Y os mii i a lt 2 kz zi u c Ej pem J 2 ze gt E E m 52 5 144 PL Bii m 8 z a B ERR lt c S s 5 S z 2 54 zz o o z 9 zo 85 2 r gt c Ez EZ tw a I uu Su c 86 38 pog ae 5 2 9 2 8 of 8 o o FIKSI ME PONI kuu SET SCREWS F2 3 MIN SECT N N SECT P P SECT W W 8 X X SECT Y Y 8 ZZ S Figure 3 7 Circuit Controller Adjustment and Shaft Assembly Diagram SM 6263 Rev 7 June 2009 3 9 5 Operation 77 AnsaldoSTS Instructions for shifting the cams to reverse the ends of the stroke at which they have their notches up and for adjustment of the contacts are given in sections 2 11 2 and 5 5 6 2 respectively 3 3 2 Motor Control Contacts Of the four sets of motor control contacts Figure 3 5 the two on the right side viewed from lock rod end of machine are open and the two on the left side are closed when the machine is in the position shown When the machine reaches full opposite position the closed contacts have been opened to break the motor circuit and the open contacts are closed to provide a circuit for operating the machine back to its original position Each set of motor control contacts pro
62. acement Machines 7 TWO WIRE CONTROL FOR ALSTOM GRS REPLACEMENT MACHINES 7 1 Configuration Guide Table 7 1 lists the available configurations for the ALSTOM GRS replacement switch machines Table 7 2 lists the assemblies for these switch machines Table 7 1 ALLSTOM GRS Replacement Switch Machine Configuration Guide Reference Description 15W 115 230V heater N253225 in circuit controller compartment LH machine set up for RH indication or RH machine set up for LH indication 15W 115V heater N296580 004 in motor compartment With telephone jack in circuit controller compartment 7 2 Switch Machine Assemblies Table 7 2 ALLSTOM GRS Replacement Switch Machine Assemblies Left Hand Right Hand Motor Gear Ratio N451160 0330 N451 160 0331 110 VDC 189 1 N451160 0338 N451 160 0339 C S T U 110 VDC 189 1 7 3 Switch Machine Parts List Table 7 3 ALLSTOM GRS Replacement Switch Machine Parts List Heater For Motor Compartment Not Shown N296580 004 Screw 8 32 X Flat Head SM 6263 Rev 7 June 2009 7 1 5 3 Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS Description Part Number 12 Amp Diode Assembly N451005 02 Contactor Assembly N451161 5303 153 Listed part numbers are either alternates or additions to the parts list shown in Table 6 5 Contactor N451161 5303 was no longer available starting October 2005 It was used in all replacement switch m
63. achines manufactured prior to that date Contactor N410011 01 is a direct replacement but harness N451161 5904 must be used along with it Contactor N410011 01 was used in all replacement switch machines manufactured beginning October 2005 Harness N451161 5904 will work in all replacement switch machines but is longer than the N451161 5902 harness To use the 5904 harness in machines manufactured prior to October 2005 adjust the harness routing within the machine to allow for the extra length 7 2 SM 6263 Rev 7 June 2009 j Z AnsaldoSTS Two Wire Control for ALSTOM GRS Replacement Machines Normal Reverse WR Normal Reverse NWR ee a ee he eh ee et 10VDC as i mo Figure 7 1 Two Wire Control Circuit Sheet 1 of 2 SM 6263 Rev 7 June 2009 7 3 n Two Wire Control for ALSTOM GRS Replacement Machines AnsaldoSTS LPNC Normal 7 Reverse WR Normal NWR Figure 7 2 Two Wire Control Circuit Sheet 2 of 2 7 4 SM 6263 Rev 7 June 2009 Two Wire Control for ALSTOM GRS Replacement Machines 77 AnsaldoSTS Ag HOLOW 1 HOLOVLNOO NI 2 G3 18 N3SSY 38 OL HOLOVLNOO SINAWAYINOAY NOILONYLSNOO LINS OL 91315 3H LNI 38 OL ASSHL QUVOS TVNINUAL NIV OL3LL 8 1V3S OVE V NI 575
64. applications If the latch see Section 3 4 is arranged to be self restoring the control and indication circuits should be examined before installing the switch machines to make sure that the circuits will not prevent the machine from operating to restore the latch automatically following a latch out machines have two leads from the main terminal board to the circuit controller compartment to accommodate the application of a circuit controller heater in the field if the machine is not already so equipped see Section 3 9 2 8 Initial Lubrication Apply a light coat of gear lubricant Spec M 7652 3 shipped with the machine to the teeth of the spur gear only Put the remainder of the lubricant into the worm gear compartment to a level no higher than the top of the worm gear See lubrication chart in Figure 5 3 and Figure 5 4 AII 2 12 SM 6263 Rev 7 June 2009 5 AnsaldoSTS Installation and Adjustments other working parts of the machine have been sufficiently lubricated at the factory and do not require additional lubrication at this point NOTE When applying lubricant it is not necessary to remove the oil slushing compound with which parts are factory coated to provide protection against corrosion during shipment and storage The pins holding the lock rod control rod point detector control rod and operating rod should also be lubricated at this time 2 9 Lever Position and Interlock In g
65. are ordinarily held tightly against the upper and lower flanges of the core by the compression force of the spring When the selector lever is operated 180 degrees from the position shown one end of the selector clutch yoke will lift such that its lower rollers push upward against the underside of the flange on the lower spring cup If the switch is in the position corresponding to the position of the hand throw lever such that the tooth of the hand throw pinion is aligned to receive the tooth of the clutch for hand operation and assuming no restraining friction between the teeth at the bottom the selector clutch assembly will shift upward without deflecting the spring At times however there may be a torque load on the lower teeth when the selector lever is operated for example if the switch is stalled on an obstruction and this may cause sufficient friction to hold the clutch down while the yoke is lifted As a result the spring will be compressed as the lower spring cup is lifted by the lower rollers on the yoke until the top of the lower spring cup engages the bottom of the upper spring cup Further operation of the selector lever provides a positive drive to pull the lower teeth apart far enough that the chamfered corners of the teeth engage instead of the nearly vertical working faces At this point the single tooth at the top of the clutch assembly is raised enough to begin engaging the hand throw pinion and will be forced into full en
66. ate 3 3 1 Indication Contacts The four sets of indication contacts operate as two pairs one pair indicating the normal position and the other indicating the reverse position Each pair is operated by a single cam and both are subject to point detector operation Wiring and wire nomenclature are standardized so that the left pair of contacts L Figure 3 5 Sect Figure 3 7 are used to indicate normal on all installations This means that in some applications the left pair of contacts must indicate that end of the stroke that has the slide bar toward the lock rod end of machine and in other applications must indicate that end of the stroke that has the slide bar toward the motor end of the machine The right pair of contacts M Figure 3 5 similarly must indicate sometimes one end and sometimes the other end of the slide bar stroke so as to indicate reverse Referring to Figure 3 6 when cam has its notch up the associated normal pair of contacts L closes as shown except when prevented by point detection as explained later For a right hand layout with right hand point normally closed cam N has its notch up when the slide bar is at that end of its stroke where it is nearest the motor end of the machine At the same time cam P is holding its associated pair of contacts up Sect P P and Sect N N of Figure 3 7 When the machine is operated towards the opposite end of its stroke the notch in cam N rotates countercl
67. avoid changing their position when removing the bolt 5 5 Assembly 5 5 1 Reinstallation of Gearbox M 3 Refer to Figure 6 1 Place gearbox onto switch machine base Align mounting holes in gearbox with holes in the base Install four screws 134 Install push rod by inserting the pin into the housing and lowering the push rod Install push rod 27 by sliding the cutout contact end through the shaft 31 Align the holes at the end of the push rod with their respective swivels and install the two screws Mount and adjust knob to yoke 5 5 2 Gearbox Reassemble Dual Control M 23A and M 23B RH to LH LH to RH Refer to Figure 3 12 and Figure 3 13 a Transfer the yoke support H to the other hub rotate yoke 180 degrees and reapply eccentric bushing bolt G without disturbing eccentric bushing positions SM 6263 Rev 7 June 2009 5 5 5 6 lt Shop Maintenance AnsaldoSTS b Reapply lever assembly to the hub on opposite side of gearbox with shaft splines entering hand throw gear F and with eccentric pin P on selector shaft entering the slot on the end of the yoke With hand throw lever vertical reapply set screw F1 in hand throw gear F Reapply 1 27 13 bolts A2 to secure yoke support H and replace the two top bolts A4 to hold lever shaft bearing M in place In order that Motor position of selector lever will be toward motor end of machine as indicated for standard assemblies in Diagram A B C or D of Figure 2 9
68. chine when shipped showing how external connections are to be made to the main terminal board for a particular application To allow standardized wiring provision is made in the circuit controller for arranging it to always have certain contacts indicate Normal regardless of which end of the operating stroke is established as Normal The internal wiring includes wires for an electric heater that can be added in the circuit controller An electric heater for the motor compartment is also available 1 3 Operating Mechanism The M 3 see Figure 1 1 and M 23A and M 23B see Figure 1 2 machines each contain three compartments a Motor compartment housing the motor This compartment also contains the main terminal board and has a wire outlet for the external wiring The friction clutch of the gear train projects into this compartment b Gearbox housing the gear There are two compartments in the gearbox one for the spur gear portion of the reduction gearing and the other for the main crank and worm gear drive Connection between the spur gears and the worm shaft is through the friction clutch which projects into the motor compartment as mentioned in paragraph The friction clutch protects the mechanism from shock at the end of the stroke or when travel is stopped suddenly by an obstruction in the switch point or by lock rod fouling The gearbox also houses the mechanism for operation by a hand crank M 3 or by the dual control mechani
69. clutch housing tubular neck so that the clutch housing is driven by the motor Drive between the clutch housing and the worm shaft is through the friction discs SM 6263 Rev 7 June 2009 3 17 5 Operation AnsaldoSTS 3 6 Operation By Hand Crank M 3 Only Provision is made in the M 3 switch machine for hand operation by inserting a removable hand crank through the hand hole in the gearbox cover Motor cutout contacts O Figure 3 5 are operated by means of a linkage to open the motor circuit and in some cases to open a control circuit when the hasp for the hand hole cover is released and the crank inserted Latch X which can be removed if not desired serves to hold the motor cutout contacts latched out until reset manually a useful feature when someone other than the signal maintainer is authorized to use the hand crank In certain cases particularly on transit properties clearance is such that the hand crank may contact the vehicle collector shoe and present a personal and equipment hazard Do not permit traffic through the switch area unless the hand crank has been removed 3 7 Dual Control Mechanism M 23A and M 23B Only Switch operation switch locking and circuit controller operation are all performed by the vertical main crank in the gear compartment shown in Figure 1 2 This crank is always in engagement with either a the motor through the reduction gear train and its friction clutch or b
70. controller compartment Machines are shipped from the factory with the selector lever assembled for MOTOR position toward the motor compartment If the lever assembly is reversed in the field the transfer must be made while the crank finger on the end of the shaft is at the bottom of its stroke to force the selector clutch down toward its motor position Be sure to reassemble the lever support to shift the hole for the ball to meet the requirements in the preceding paragraph Similarly if a stop screw is applied to one of the ball recesses in the hand throw lever hub as previously described it must be shifted so as to be on the side of the shaft opposite to that for MOTOR position of the selector lever SM 6263 Rev 7 June 2009 5 13 A Shop Maintenance AnsaldoSTS 5 6 Lubrication Before leaving the factory all working parts of the machine except the worm gear compartment are well lubricated Unpainted and unplated parts are coated with a special lubricant designed to protect these parts against corrosion until installation This lubricant need not be removed since it will mix readily when new lubricants are added For best results only lubricants complying with strict specifications are recommended The recommended lubricants can be purchased in convenient quantities from ASTS USA Figure 5 3 and Figure 5 4 identify the areas of the switch machine that need lubrication These points and the proper lubrication are further described i
71. crews 47 Figure 6 1 46 Figure 6 2 at rear of motor s mounting bracket commutator end Remove two associated 1 2 plain lock washers Lift motor assembly 4 up and pull towards conduit outlet until pinion gear on motor shaft is clear of motor opening If required remove pinion from shaft and motor from bracket using Allen wrenches 5 4 3 Removal of Friction Clutch Assembly Refer to Figure 5 1 Remove cotter key 11 from clutch adjusting nut 10 Remove clutch adjusting nut 10 from worm shaft Remove clutch spring 9 Remove two cap screws 13 securing plate Remove plate and gasket Pull clutch housing tubular neck 7 out of engagement with gear hub Continue to pull until tubular neck is clear of opening in gearbox exposing worm shaft 5 2 SM 6263 Rev 7 June 2009 5 AnsaldoSTS Shop Maintenance CA ik S UNE EPA A ZN Ma BER E pR ME 6 CluthhD k Ci ACES 8 CluthEndPlte 46575 9 Clutch Spring 292 3 11 Cotter 3 16 x2 TinPlL deo Cap Screw 1 4 20 x 3 4 Hex Tin PI Figure 5 1 Friction Clutch Assembly 5 4 4 Removal of Circuit Controller Refer to Figure 6 1 Remove circuit controller cover 36 Tag and remove wires attached to circuit controller terminals and heater Position wiring harness out of way by removing the four wire clamps screws and lock washers Re
72. cts are prevented from indicating even though the points may subsequently spring back and leave the point detector bar near its original position Thus protection is provided in case the switch points have been damaged in such a way as to be unsafe for facing point traffic yet so distorted as to leave very little net shift of the point detector bar The latch is equipped with a self restoring feature which may be readily removed if not wanted to take care of situations where the latch may become unnecessarily latched up due to unusual traffic shocks that do not affect the fit of the switch point against the rail The latch will reset automatically when the machine is next operated to withdraw the locking dog from the lock rod notch If the latch were latched up as the result of damage to the switch point it would be impossible for the machine to complete its stroke in either direction due to lock rod fouling The latch can also be reset manually Major components of the point detector mechanism are shown in Figure 3 5 and the relative positions of the eccentric bushings operating rods and point detector rollers for the normal position of the switch machine are shown in Figure 3 8 Mid stroke positions of the various parts are shown in Figure 3 9 Reverse positions of the various parts are shown in Figure 3 10 while Figure 3 11 shows the various parts latched up in the reverse position The right and left hand operating crank springs hold the yo
73. downward should the point detector bar be displaced When the machine is operated out of the normal position the controller shaft rotates in a counterclockwise direction viewed from right hand side and the operating levers are shifted by the eccentric bushings so as to move point detector roller A away from the point detector bar and permit movement of the point detector bar from the normal to reverse position without contacting either roller Mid stroke positions are shown in Figure 3 9 Reverse positions of the parts are shown in Figure 3 10 Both rollers are again clear of the bar but roller B is in position to deflect the yoke downward should the point detector bar become displaced The latched out position of the circuit controller is shown in Figure 3 11 In this position the point detector bar has been shifted from its reverse position due to deflection of the switch points caused by improper trailing The large diameter of the point detector bar has been brought into contact with point detector roller B resulting in the connecting rod shifting the operating levers and thereby rotating the yoke downward about the controller shaft until the latch as biased by the latch spring snaps over the top of the yoke midsection As yoke is rotated downward the upright cam portion of the yoke engages the roller on the under side of both indication contact assemblies and thereby lifts the reverse contact assembly to open the reverse indicatio
74. e 6 3 M 23B Switch Machine Assemblies sse 6 4 M 3 Switch Machine Single Switch Parts List 4404 6 5 M 23A and M 23B Switch Machine Single Switch Parts List 6 10 M 3 Gear Box Parts 2 4 00 01 nnne nnne nnns nnne nens 6 16 M 23A and M 23B Gear Box Parts List sse 6 19 M 3 M 23A and M 23B Indication Circuit Controllers see 6 23 M 3 M 23A and M 23B Standard Base 6 27 M 3 M 23A and M 23B Motor Assemblies 6 27 M 3 M 23A and M 23B Motor Brushes 6 28 ALLSTOM GRS Replacement Switch Machine Configuration Guide 7 1 ALLSTOM GRS Replacement Switch Machine 7 1 ALLSTOM GRS Replacement Switch Machine Parts 15 7 1 Contactor Assembly N451 161 5303 Parts 7 6 Contactor Assembly N410011 01 Parts List 7 9 Motor Assembly N451161 1706 Parts List 7 12 SM 6263 Rev 7 June 2009 A AnsaldoSTS General Information 1 GENERAL INFORMATION 1 1 Introduction This service manual covers the M 3 M 23A and M 23B electric switch machines with permanent magnet motors Mechanically and functionally there are
75. e a selector lever to permit manual or power operation and a hand throw lever it is this provision which requires a different gearbox The M 23A and M 23B machines may also be hand operated by applying a ratchet wrench to the friction clutch adjusting nut The M 23A machine differs from the M 23B machine in that it uses a different hand throw pinion which affects the hand throw locking Power operation is the same in both machines In the M 23A machine operation by the hand throw lever gives the same mechanism stroke including full lock rod protection as power operation In the M 23B machine however operation by the hand throw lever does not provide lock rod protection the slide bar and lock box do not move full stroke Motors and gear ratios are available for operating the machines using either 110 or 20 VDC and may be changed without changing the gearbox Two gear ratios are available for the low voltage 20 VDC machines one to provide relatively fast operation as used generally and the other to provide slower operation for use at locations where current requirements must be held to a minimum third gear ratio is used with the high voltage 110 VDC motors SM 6263 Rev 7 June 2009 1 1 Ay General Information AnsaldoSTS The machines are completely wired at the factory with the internal wiring connected to the main terminal board in the motor compartment A typical wiring diagram or working drawing is enclosed with each ma
76. e plates tie straps rail braces and switch fittings are secure c Check that there are no signs of water accumulation around switch machine proper drainage exists d Remove any material within layout that could obstruct switch movement 4 1 3 Switch Machine Inspection Perform switch machine inspection as follows a Remove covers from switch machine circuit controller gearbox and motor compartments b Using hand crank for M 3 or hand throw lever for M 23 operate switch back and forth as often as necessary and check for Proper and smooth operation of switch points without undue drag or spring and with points riding on all slide plates Also check for switch point obstructions at this time Loose or damaged electrical connections Burned frayed or broken insulation Proper movement of switch machine main crank slide bar lock box switch operating bar circuit controller shaft and circuit controller point detector connecting rods Excessive wear lost motion or accumulation of foreign or conductive material Excessive or unusual vibration and noise c Electrically operate switch machine and check for 1 Smooth movement of switch machine motor and gears no binding etc should be noticed 2 Conditions listed in step b above d Check that there are no signs of moisture accumulation within switch machine compartments 4 2 SM 6263 Rev 7 June 2009 A AnsaldoSTS Field Maintenance e Durin
77. ecessary per Section 5 7 2 c Check wiring for proper connections d Check the clutch adjustment With an obstruction of at least 3 8 between the switch point and the stock rail electrically operate the machine When the switch point jams against the obstruction the worm gear and worm shaft will be stopped but the motor should continue to run during the overload time delay period slipping the friction clutch Motor current during this period should be within 10 of the values specified in Table 5 2 Section 5 5 5 3 If necessary readjust the friction clutch spring to obtain the specified clutch slip current NOTE If the friction clutch slips too easily the motor current may not operate the overload relay and battery exhaustion may occur If the friction clutch adjustment is too tight unnecessary wear on the mechanical parts may occur due to absence of shock protection In ordinary operation without obstruction of the switch points the clutch might slip slightly at both ends of the power stroke 2 11 Supplemental Information This section provides additional specific information on the following a Changes that may be necessary in the assembly at the time of installation if the switch machine as ordered does not suit conditions at the location b Inverting lock box to agree with lock rod notching c Shifting indication cams to have contacts at left indicate Normal d Converting between high voltage and low v
78. eneral the position of the selector and hand throw levers will be as shown in Figure 2 9 and the interlock will ordinarily permit the selector lever to be returned to its MOTOR position when the hand throw lever is in either the Normal or Reverse position However certain deviations from these usual standards are feasible The various arrangements are as follows a Both levers must always be on the field side of the machine that is on the left side for a LA machine and LH layout and on the right side for a RH machine and RH layout To change between RH and LH refer to Section 5 5 2 b The hand throw lever will always move the switch in the direction to close the near point when the lever is operated toward the motor end of the machine This characteristic cannot be changed c For the standard arrangement the selector lever is assembled to be toward the motor end of the machine when the lever is in its MOTOR position as shown in Figure 2 9 When desired however the lever can readily be assembled to be toward the circuit controller end of the machine for MOTOR position and the interlock arranged to suit as described in Section 5 5 The cast MOTOR and HAND marker plates on the selector lever are interchangeable d The lever interlock can be arranged to either 1 allow the selector lever to be returned to MOTOR position when the hand throw lever is in the Normal or the Reverse position or 2 require the hand throw lever to be in Normal pos
79. ents are not possible due to all of the manufacturing tolerances This procedure is a guideline for adjustment c Ensure that there is enough contact pressure to prevent failures due to vibrations created by train movement 5 7 2 3 M 23A and M 23B Switch Machine Motor Cutout Contacts Motor cutout contact for the Styles M 23A and M 23B should open when the selector lever is lifted 6 out of MOTOR position measured at the hand grip and be open 1 8 min To 3 16 max when the selector lever is in the HAND position When the selector lever is in MOTOR position the end of the push rod should be 1 16 clear of the contact operating bar and the contacts should be closed with 1 1 2 Ib Mm To 2 Ib Max pressure Adjustment of the closed pressure when necessary is made by careful use of a spring bender The linkage which affects the operation should be maintained in adjustment as follows With selector lever in MOTOR position the rocker arm Figure 5 9 should be screwed up or down as necessary to just touch the machined cam surface on the selector yoke Then the adjusting rod should be turned so that its eccentric head holds the end of the push rod 1 16 clear of the contact operating bar SM 6263 Rev 7 June 2009 5 23 5 Shop Maintenance AnsaldoSTS ROCKER ARM MOTOR HA POSITION POSITION MOTOR CUT OUT CONTACTS Figure 5 9 M 23A and M 23B Machines Motor Cutout Contact Assembly 5 7 3 Selector Clutch Adjustme
80. es are properly installed SM 6263 Rev 7 June 2009 5 7 EN Shop Maintenance 7 AnsaldoSTS 5 5 4 Reinstallation of Motor Refer to Figure 6 1 and Figure 6 2 Lower motor bracket onto base of switch machine so that pinion end of motor is inserted through motor shaft opening Position motor so that pinion is mated properly with reduction gear Align mounting holes in motor bracket at commutator end with holes in base of switch machine Insert two 1 2 13 x 2 hex head cap screws 47 Figure 6 1 44 Figure 6 2 and two associated 1 2 plain lock washers in motors mounting bracket commutator end Reattach wires to motor connections Replace motor cover 40 5 5 5 Reinstallation of Friction Clutch Assembly Refer to Figure 5 1 Before assembly check that the friction discs 6 are free of oil If clutch discs are oily and it is found that oil is entering along the shaft it is recommended that the felt pad and oil seal be renewed in the clutch housing Refer to Section 5 5 5 1 If the felt washer and oil seal are not to be replaced continue with Sections 5 5 5 2 and 5 5 5 3 5 5 5 1 Instructions for Replacing Felt Washer and Oil Seal in Clutch Housing Refer to Figure 5 2 Measure the length of clutch spring before disassembling and record this dimension as information for reassembling Swing terminal board out of the way remove the adjusting nut and clutch spring and slide the clutch housing off the shaft Remove the discs and
81. g semi annual inspections check for moisture in the compartments If 3 8 inch pipe plugs are installed in two drain holes located in the crank case compartment or slotted head bolts with lock washers are installed in circuit controller compartment remove plugs and allow whatever moisture is present to drain from compartment CAUTION Where drain plugs are used a moisture check should be made prior to anticipated freezing weather A freeze up of excessive moisture could result in improper switch machine operation f Reinstall plugs in drain holes NOTE These pipe plugs should have been installed initially only if the switch machine is in a location where blowing sand or dust is troublesome otherwise drain holes should be open During cold weather periodically check that the holes are open g Check that motor control contacts indication contacts motor cutout contacts and associated cams and linkages are clean and do not show excessive wear Refer to Section 4 3 h Check that all switch machine parts are properly and adequately lubricated Refer to Section 5 6 i Check that conduit between switch machine motor compartment and junction box is not crimped nicked cut or otherwise damaged Remove two screws securing access plate over motor commutator 1 Check that commutator is smooth and clean 2 Check that commutator brushes are free in their holders and are not excessively worn 4 2 Cleaning
82. gagement with it by the spring force and any upward thrust due to the torque load on the lower teeth provided that the two upper teeth are aligned to permit this If these upper teeth are not aligned the spring will hold the clutch for hand operation against the hand throw pinion tooth until the hand throw lever is operated to obtain alignment The spring functions in a similar manner if the worm gear teeth are not aligned when the selector lever is returned to the motor position SM 6263 Rev 7 June 2009 3 19 5 7 Operation AnsaldoSTS CLUTCH FOR HAND OPERATION UPPER ROLLER ROLLER SELECTOR CLUTCH SPRING SELECTOR LEVER SHAFT LOWER SPRING CUP SELECTOR CLUTCH YOKE CLUTCH FOR MOTOR OPERATION LOWER ROLLER MAIN CRANK NOTE SELECTOR CLUTCH ASSEMBLY COMPRISES PARTS MARKED UPPER SPRING CUP BEARING CAP HAND THROW BEVEL GEAR HAND THROW LEVER SHAFT qa SELECTOR LEVER SHAFT A HAND THROW PINION gt En CLUTCH FOR HAND OPERATION ECCENTRIC BUSHING 77 A SELECTOR CLUTCH YOKE SELECTOR CLUTCH SPRING LOWER SPRING CUP CLUTCH FOR MOTOR OPERATION WORM GEAR MAIN CRANK SHAFT Figure 3 14 Sectional Views of M 23A Dual Control Mechanism 3 20 SM 6263 Rev 7 June 2009 N 77 AnsaldoSTS Operation Operation of the selector lever out of the motor position also actuates a pair of mot
83. gure 7 6 Figure 7 7 Figure 7 8 77 AnsaldoSTS Table of Contents Motor Cutout Contacts and 5 19 Yoke and Bearing nennen nnnm 5 20 Machine in Hand Operation Covers 5 22 Machine in Motor Operation Covers 5 22 M 23A and M 23B Machines Motor Cutout Contact Assembly 5 24 M 3 Switch Machine Single Switch Parts 4 0 6 9 M 23A and M 23B Switch Machine Single 6 15 M 3 Switch Machine Gear Box Parts 6 18 M 23A and M 23B Gear Box Parts 6 22 Indication Circuit Controller Parts 6 26 M 3 M 23A and M 23B Blue Motor 6 28 M 3 M 23A and M 23B Black Motor 6 29 M 3 M 23A and M 23B Gray Motor 6 30 Two Wire Control Circuit Sheet 1 of 2 7 3 Two Wire Control Circuit Sheet 2 of 2 7 4 Two Wire Control 7 5 Contactor Assembly N451161 5303 Parts 7 7 Contactor Assembly N451 161 5303 X and Y Label Location 7 8 Contactor Assembly N4
84. h machine is locked in accordance with AREMA specifications Ordinarily readjustment will not be required as long as the assembly remains undisturbed If an adjustment is required proceed as follows a Clean and degrease the contacts with a suitable cleaner b With the machine in an unlocked position insert a 1 2 0 0 01 x 2 x 24 steel bar into the lock rod slot Turn the clutch housing by hand until the lock dog bears against the bar In this position the machine is fully locked c Connect an ohm meter or test light across one of the appropriate control contacts SM 6263 Rev 7 June 2009 5 11 A RT Shop Maintenance AnsaldoSTS d Loosen the nuts which hold the V end of finger F1 and slide the finger in or out until a point where any additional cam rotation will open the contact Retighten the nuts When a 15 32 4 07 0 01 x 2 x 24 steel bar is used for the aforementioned test the contacts should be open e Repeat the procedure for the other three motor control contacts Check to see that adjacent control contacts open simultaneously Contact finger should be adjusted to bear against the segment with 2 to 2 1 2 165 pressure while the finger F2 is held clear Adjust finger stop Fla to have 1 32 1 64 clearance from finger F1 when the latter is riding the segment Adjust ringer F2 to bear on finger F1 with 1 3 4 to 2 165 pressure when finger is on the segment Adjust stop F2a to clear finger F
85. il is entering along the shaft it is recommended that the felt washer and oil seal be renewed in the clutch housing as described in Section 5 5 5 1 4 5 2 Switch Machine to Switch Adjustments If it is necessary to readjust the switch machine refer to Section 2 Installation and Adjustments Sections 2 3 2 4 and 2 5 4 5 3 Motor Control Contacts Adjustment Refer to procedures provided in Section 5 5 6 1 4 5 4 Indication Contacts Adjustment Refer to procedures provided in Section 5 5 6 2 4 5 5 Motor Cut Out Contacts Adjustment Refer to procedures provided in Section 5 7 2 SM 6263 Rev 7 June 2009 4 5 A Field Maintenance AnsaldoSTS 4 6 Repair Procedures Repair of the switch machine in the field consists of removing and replacing the motor brushes and major switch machine assemblies It is not recommended that major overhaul or repair to the machine requiring disassembly to the component part level be done in the field The switch machine should be removed from service and sent to the ASTS USA service or repair shop for this level of repair To remove the switch machine from service refer to Section 2 Installation and Adjustments and reverse the order of the steps listed To remove and replace the brushes and major assemblies remove and replace a Motor Brushes Refer to Sections 5 4 1 and 5 5 3 b DC Motor Refer to Sections 5 4 2 and 5 5 4 c Friction Clutch Assembly Refer to Sections 5 4
86. in place Reinstall covers Reinstallation of Motor Brushes Refer to Section 6 7 Before installing the motor brushes check that the motor commutator is smooth and free from grease and oil To dress the commutator use a fine grain commutator stone or a piece of No 00 sandpaper Never use emery cloth for cleaning the commutator or brushes These commutators must not be undercut a For Blue Motor Machines Motors BA 3640 4418 56C BA 3636 4419 56C BA3640 4420 56C with external brush covers Type B Fit brushes to commutator using No 00 sandpaper Install motor commutator brush in holder Install spring hold down by pushing into slot beside brush and hooking it over the end of the brush holder Repeat for other brush Check that motor commutator brushes are free in the holders Install motor brush commutator covers with two screws on each cover Install motor cover 40 Operate switch machine motor to determine if brushes are properly installed For Gray Motor Machines Motors D 422305X6432 D 42206X6532 and D422307X6632 with brush band cover Type A Brushes are provided with radius to fit commutator therefore sanding of brushes is not recommended Retract brush hold down spring insert brush into holder and release spring Terminate brush lead to terminal Repeat for other brush Position brush commutator cover over access holes and tighten screws Install motor compartment cover Operate switch machine to verify brush
87. is inspected cleaned lubricated and performance tested in the field on a periodic basis The preventive maintenance procedures outlined herein ensure that all switch machine functions are operational A recommended schedule for performing preventive maintenance tasks is shown in Table 4 1 The actual time interval will depend on the customers own operating rules and or experience Table 4 1 Preventive Maintenance Schedule Functional Circuit Maintenance Action Interval or Equipment Route Insp Perf Test Monthly Switch Layout EES Semi annually Switch Machine E ON I j Semeank ali Switch Machine Circuit X y Controller Compartment Semi annually Switch Machine Doo X Monthly Switch Machine l 4 1 1 Inspection Inspection is conducted in two areas the switch layout area and the switch machine itself Inspection consists of observing the appearance and integrity of the switch points switch rods connecting rods possible switch obstructions electrical connections and the interior of the switch machine A judgment is then made as to whether a potential or obvious faulty condition exists When any faulty condition is observed it is to be corrected immediately SM 6263 Rev 7 June 2009 4 1 A Field Maintenance 77 AnsaldoSTS 4 1 2 Switch Layout Inspection Perform switch layout inspection as follows a Check that ties are well tamped to withstand vibration and strain caused by passing trains b Check that ti
88. itch control circuits using the PP 151 and PN 150BM relay combinations Figure 2 5 through Figure 2 8 view C are typical switch control circuits using two PN 150BM relays in place of the PP 151 PN150BM combination The DP 25 PNP 69 and PN 150BM relays are capable of breaking stalled switch motor current in excess of 50 amps at 110 VDC For switch machine installations with shelf type relays the DP 25 is used It is available with two neutral magnetic blowout contacts for a double break switch motor circuit Conversion of the DP 25 relay with one magnetic blowout contact without low voltage neutral contacts to one having two magnetic blowout contacts can be accomplished by following Service Specification SM 2378N The typical circuits shown are intended to illustrate principles and should not be used as working drawings Pole changing contacts and other circuits not shown for control of the WR relay should be in accordance with the circuits designed for the specific installation For converting between five and three wire control refer to paragraph 2 11 4 If the layout calls for a left hand point normally closed interchange leads as called for in the note on Figure 2 5 Figure 2 6 Figure 2 7 and Figure 2 8 The circuit controller cams for the indication contacts should also be reversed as outlined in Section 2 11 2 An internal wiring diagram is enclosed with each switch machine when shipped Consult ASTS USA for specific field wiring
89. ition only before a selector lever can be returned to MOTOR position Machines are shipped with option 1 assembly unless the order specifies that hand throw lever must be Normal only SM 6263 Rev 7 June 2009 2 13 A uw Installation and Adjustments AnsaldoSTS LEVER LEVER INTERLOCK ASSEMBLY INTERLOCK STOP SCREW WHEN USED DIAGRAM A L H LAYOUT L H POINT NORMALLY CLOSED ASSEMBLY STOP SCREW WHEN USED DIAGRAM B R H LAYOUT R H POINT NORMALLY CLOSED 6A2 0025 00 LEVER INTERLOCK ASSEMBLY STOP SCREW WHEN USED Lc DIAGRAM L H LAYOUT L H POINT NORMALLY OPEN 0000 LEVER INTERLOCK ASSEMBLY STEEL BALL STOP SCREW WHEN USED mi DIAGRAM D R H LAYOUT R H POINT NORMALLY OPEN 2 14 Figure 2 9 M 23 Switch Machine Standard Lever Interlock Assemblies SM 6263 Rev 7 June 2009 A AnsaldoSTS Installation and Adjustments 2 10 Prior To Placing Machine In Operation a Check the lids for proper fit Adjust if necessary b Check the motor cutout to be certain it is operating properly Be sure that the crank cannot be inserted without the cutout contacts being latched out Adjust if n
90. ke which is pivoted on the controller shaft against the yoke stop on the latch bracket for all controller positions except when the point detector bar has been displaced due to improperly positioned switch points That is for normal operation of the machine with the switch points in proper adjustment the yoke assembly remains in a fixed position as shown in Figure 3 8 Figure 3 9 and Figure 3 10 Parts are illustrated for machine in which cams are assembled for Normal end of stroke to be that which places switch points to the right SM 6263 Rev 7 June 2009 3 11 5 Operation 77 AnsaldoSTS POINT DETECTOR ROLLER B OPERATING LEVER EE s CONNECTING E PIN CAM ON YOKE SHAFT GEAR OPERATING LEVER ECCENTRIC BUSHING CRANK SPRING POINT DETECTOR CONN CTING ROD ROLLER A OPERATING PIN Figure 3 8 Schematic Diagram of Point Detector Parts in Normal Position POINT DETECTOR ROLLER CRANK SPRING OPERATING LEVER CONNECTING ROD OPERATING LEVER ECCENTRIC BUSHING CRANK SPRING POINT oe CONNECTING ROD EA OPERATING PIN Figure 3 9 Schematic Diagram of Point Detector Parts in Mid Stroke Position 3 12 SM 6263 Rev 7 June 2009 2 77 AnsaldoSTS Operation eos ROLL CRANK SPRING o CRANK pow qu OPERATING LEVER XU QU WU CONNECTING ROD Ox OPERAT
91. l Pinions for M 23A and M 23B Switch Machines Lever Interlock The hand throw and selector levers are interlocked by means of a steel ball and suitable recesses in the lever hubs to prevent operation of the hand throw lever unless the selector lever is in the HAND position and also to prevent return of the selector lever from its HAND position unless the hand throw lever is in one or the other of its full stroke positions The interlock can also be assembled to require that the hand throw lever always be returned to Normal before the selector lever can be returned from its HAND position Details of the interlock are illustrated in Figure 2 9 and described in section 2 9 Moreover it is possible to apply the selector lever to its shaft in either of two ways 180 degrees apart so as to have the MOTOR position of the selector lever toward either the motor end or the circuit controller end of the machine for both right hand and left hand assemblies 3 8 Motor 3 8 1 Motors Available Two 20 VDC and two 110 VDC motors are available The 20 VDC motors are used on switch machines with gear ratios of 360 1 and 528 1 The 110 VDC motor is used on switch machines with gear ratios of 189 1 and 360 1 For low voltage motors under the most adverse conditions of load temperature and battery voltage the Voltage at the battery terminals should not be less than 20 VDC 110 VDC motors should have not less than 85 volts at the motor terminals The voltage a
92. move the two screws 6 and lock washers attached to the feet of the circuit controller nearest the motor compartment Remove the two screws 74 SM 6263 Rev 7 June 2009 5 3 A Shop Maintenance AnsaldoSTS lock washers and plate 9 located between the point detector cranks Lift and remove circuit controller from compartment If further disassembly is required see Figure 6 5 5 4 5 Gearbox Removal M 3 Refer to Figure 6 1 Disconnect pull knob from yoke Remove the two screws located on either side of the cotter key 70 that links the push rods and the motor cutout contact controls Remove push rod 27 by holding it at the end nearest the motor compartment and pulling it until the opposite end clears the shaft 31 Remove push rod by lifting and pulling it until the pin at the other end clears the hole in the side of the housing Remove the four screws 134 that secure the gearbox to the base Lift gearbox from base of switch machine If further disassembly of the gearbox is required see Figure 6 3 NOTE Before proceeding with further disassembly the maintainer should be thoroughly familiar with the information and illustrations found in Sections 1 and 3 These illustrations will aid in final disassembly of the switch machine 5 4 6 Removal of Main Crank For all three machines M 3 M 23A and M 23B it is necessary to take out the main crank through the bottom of the machine To do this the bottom cover and
93. n As shown in Figure 3 5 the circuit controller has a total of 8 sets of contacts operated by cams and segments on shaft R which is rotated by the slide bar motion transmitted through the lock box rack teeth the idler pinion and the shaft gear The two sets of contacts at the left side viewed from lock rod end of the machine Figure 3 5 and the two at the right side comprise the motor control contacts while the four intervening sets comprise the indication contacts The motor control contacts are operated solely by the shaft carried segments but the indication contacts are also subject to point detector operation SM 6263 Rev 7 June 2009 3 5 5 Operation 77 AnsaldoSTS A TYPE GENERALLY USED WITH BALL AND SOCKET CONNECTION B TYPE USED WITH RIGID CONNECTION Figure 3 4 Adjustable Lock Rods for R H and L H Operation 3 6 SM 6263 Rev 7 June 2009 2 77 AnsaldoSTS Operation MOTOR CONTROL CONTACTS TWO SETS LEFT SIDE H L 1 INDICATION CONTACTS FOUR SETS 1 2 GAGING HOLE LEGEND RIGHT SIDE MOTOR CONTROL CONTACTS TWO SETS D ROLLER F IDLER PINION GEAR G LOCK BOX H EYE ROD J SCREW K MOTOR CONTROL CONTACTS L INDICATION CONTACTS LEFT M INDICATION CONTACTS RIGHT N INDICATION CAM O MOTOR CUTOUT CONTACTS P INDICATION CAM R SHAFT za JR ch m 3 Du gm SHUNTING STRIP UP
94. n contacts and to close the indication contacts against the short circuiting strip The latch can be restored manually or by operating the machine to the opposite position so that the cam on the controller shaft gear in mid stroke will lift the latch to permit the yoke to be restored to its horizontal position resting against the yoke stop 3 5 Gear Train The reduction gear train between the motor and the worm gear consists of a pinion on the end of the motor shaft one or two reduction gears clutch gear friction clutch worm shaft and worm gear see Figure 3 12 and Figure 3 13 Note that each reduction gear actually consists of two gears a large gear and a small gear made as a unit The gear ratio is changed by changing out the reduction gears using the combination listed in Table 3 1 If the latch doesn t clear the top of the yoke and operate add sufficient shims under the yoke stop see Figure 3 11 until the latch operates 3 14 SM 6263 Rev 7 June 2009 N 77 AnsaldoSTS Operation Table 3 1 Gear Ratio Reduction Gear Relationship Switch Machine M 3 M 23A or M 23B 110 VDC 110 VDC 20 VDC 20 VDC 189 1 360 1 360 1 528 1 Number of Teeth Clutch Gear 1 Reduction Ger 32 32 3 Figure 3 12 Pinion 16 16 1 27 Reduction Figure 3 12 See Operating Characteristics Paragraph 1 4 2 The pinion end of the motor is supported in an opening in the clear box which locates the pinion p
95. n Table 5 3 The following steps present the general lubrication requirements for the switch machines a Apply pressure gun grease ASTS USA Spec M 7650 01 1 Point detector bar bearings use gun on grease fittings 2 Operating bar wearing plates use gun on grease fittings 3 Selector and hand throw lever shaft bearings use gun on grease fittings 4 Surfaces of slide bar and lock box and rack G using brush or paddle for application a heavy oil viscosity 120 200 SAE 140 may be used as an alternate on these surfaces 5 Circuit controller trunnions use gun on grease fittings b Apply medium body motor oil viscosity 130 F 185 220 SAE 30 to the following parts 1 Yoke bearings and point detector linkage 2 Spur gear journals machines are equipped with Oilite bushings a Holes in box casting b Holes in reduction gears and in clutch gear NOTE Oil should be applied sparingly to clutch gear bearing to prevent seepage through clutch shaft packing to the friction discs 5 14 SM 6263 Rev 7 June 2009 w b AnsaldoSTS Shop Maintenance Top View Side View Figure 5 3 Lubrication Diagram for M 3 Switch Machine c Top View eat ie ail x ae B Figure 5 4 Lubrication Diagram for M 23A and M23 B Switch Machines SM 6263 Rev 7 June 2009 5 15 lt Shop Maintenance AnsaldoSTS 3 For M 3 machines only a Main crank shaft remove oil plug in top cover Oil
96. n and Adjustments AnsaldoSTS 2 5 Point Detector Bar Installation and Adjustment Apply the point detector bar remove shipping closures in the housing and its connecting rod Adjust to check switch point opening in accordance with AREMA Signal Section or railroad instructions When making adjustments be sure to work first with adjustments for the far switch point using the nuts on the track end of the point detector bar then adjust for the near switch point working at the field end of the point detector bar NOTE The switch operating rod point detector rod and lock rods should be kept in adjustment to meet AREMA Signal Section or railroad specifications Refer to Service Manual 5453 for a gauge available to check the point detector between periodic obstruction tests Check that indication cam N on the left side of machine center line as viewed from controller end see Figure 3 5 has its notch up when the machine is in the Normal position and that indication cam P on the right side has its notch up when the machine is in the reverse position If not shift them in accordance with the instructions in Section 2 11 2 2 6 Lever Stand Adjustment M 23A and M 23B machines Make a final check of the lever stand adjustment to assure that transfer from power to hand operation can be made under all conditions as follows a Remove the gearbox cover so that the action of the selector clutch see Figure 3 14 and its relatio
97. n the staple The motor cutout contacts should be held open by the angle bracket against latch release lever Releasing the latch release lever should close the contacts If any of the above conditions are not met the motor cutout linkage should be adjusted as per Section 5 7 2 2 5 7 2 2 Motor Cutout Contact Adjustment Remove the gearbox cover removed and verify the following a 5 18 Yoke stops against the bearing C as shown in section Z Z in Figure 5 5 1 Ifthere is a gap between yoke B and bearing inspect eyebolt L at slot in bearing C noted in top view of Figure 5 5 2 If eyebolt L rest against side of slot closest to switch machine motor loosen nut M and remove screw through eyebolt 3 Unscrew eyebolt one half revolution 4 Install screw through eyebolt from the top down and inspect eyebolt at slot 5 the yoke B rests against the bearing C tighten the nut M 6 If the eyebolt still rests against the side of the slot repeat process of unscrewing eyebolt one revolution SM 6263 Rev 7 June 2009 5 w AnsaldoSTS Shop Maintenance lt oe E GEAR BOX CIRCUIT CONTROLLER COMPARTMENT 00 Pd Et GAPS MEASURED va B WM Je Xm w CU 1 D GEAR BOX G WHEN USED NORMAL RELEASE LEVER PAD LOCK STAPLE Push Rod B Contact Insulati
98. n to the hand throw pinion can be observed as the selector lever is operated from MOTOR to HAND position b With the hand throw lever in Normal operate the machine by power to the Reverse position then back to the Normal position Operate the selector lever to HAND Check that the selector clutch shifts up engaging the tooth on the bottom of the hand throw pinion and check that the hand throw lever will operate the machine If the selector clutch fails to shift up full stroke readjust the height of the Normal hand throw lever stand to bring the clutch teeth into proper alignment c With the hand throw lever in Reverse operate the machine by power to the Normal position then back to the Reverse position Operate the selector lever to HAND Check that the selector clutch shifts up engaging the tooth on the bottom of the hand throw pinion and check that the hand throw lever will operate the machine If the selector clutch fails to shift up full stroke readjust the height of the Reverse hand throw lever stand to bring the clutch teeth into proper alignment 2 6 SM 6263 Rev 7 June 2009 5 Z AnsaldoSTS Installation and Adjustments d With the hand throw lever in Normal operate the machine by power to the Reverse position Operate the selector lever to HAND The selector clutch should ride against but not engage the hand throw pinion tooth The selector clutch spring should be compressed taking up the clearance between the upper
99. nce test on the switch layout s The performance test should be done in accordance with customer s operating rules The test should include mechanical operation of the switch mainline and electrical tests of power distribution and switch control and indication circuits Erratic or faulty operation and or indications should be promptly referred to the proper authority for corrective action 4 5 Corrective Maintenance Field level maintenance for the M 3 M 23 and M 23switch machines consists of a Friction clutch adjustment 4 4 SM 6263 Rev 7 June 2009 N m uw AnsaldoSTS Field Maintenance b Switch machine to switch adjustment c Motor control contacts adjustment d Indication contacts adjustment e Motor cutout contacts adjustment 4 5 1 Friction Clutch Adjustment The switch machine friction clutch Figure 5 1 must slip at just the right amount of torque This torque must be more than adequate to carry the switch machine s operational loading during the driving of the switch points At the same time to transmit this torque the friction clutch should not be so tight as to prevent protection of the mechanism from shock To check the friction clutch adjustment refer to Section 5 5 5 3 CAUTION Friction disks must be kept free of oil otherwise motor may be damaged due to excessive clutch slippage If contamination occurs friction disks must be replaced NOTE If clutch discs are oily and it 1 found that o
100. nd M 23B Switch Machine Single Switch Parts List Table 6 6 contains the parts list for the switch machines listed in Table 6 3 M 23A and Table 6 4 M 23B Figure 6 2 shows a location diagram for the listed parts Table 6 6 M 23A and M 23B Switch Machine Single Switch Parts List 1 Nouse Base Complete N451160 Machine Unless Noted Otherwise Suffixes 0503 0506 0513 0515 0516 0527 0528 0533 0534 0603 0606 0609 0610 0613 0616 0618 0621 0624 0633 0634 0641 0646 0657 0658 N416001 Machine Suffixes 01 02 N416002 Machine Suffixes 01 04 Suffixes 0523 0526 0529 0532 N432466 2 Suffixes 0607 0608 0611 0612 0614 0615 0617 0619 N433297 0620 0631 0632 0635 0636 0651 0656 Suffixes 0501 0502 0504 0505 0514 0517 0518 0521 0522 0537 0538 0543 0547 0601 0602 0625 0628 0637 0640 0647 0648 1201 1203 1206 1208 1213 1216 1223 1226 N416002 Machine Suffixes 03 04 Suffixes 0519 0522 0535 0536 N291057 001 M 23A Gearbox Complete N451160 Machine Unless Noted Otherwise Suffixes 0501 0508 0509 0526 0532 N287072 Suffixes 0502 0507 0525 0531 0546 0550 N287072 0001 Suffixes 0503 0504 0512 0515 0518 0521 0533 0537 0549 1210 1213 1217 1224 N287074 0001 N416001 Machine Suffixes 01 04 Suffixes 0505 0506 0513 0516 0517 0522
101. ns are required Detail instructions for changing the M 23A and M 23B dual control machines are given in paragraphs 5 4 10 and 5 5 2 After the machine has been properly assembled for the layout check the following a Two 3 8 pipe plugs are enclosed in a bag tied within the motor compartment They are for application to two drain holes located in the cover under the crank case compartment Z Figure 5 3 and Figure 5 4 when the machine is in a location where blowing sand or dust is troublesome but should not be applied unless this condition prevails and if used should be removed at intervals to drain the compartment especially prior to freezing weather b Two other drain plugs x Figure 5 3 and Figure 5 4 consisting of slotted head bolts with lock washers are provided in the circuit controller compartment These are shipped in place but not fully tightened Like the pipe plugs they should be left applied only at locations where blowing sand or dust is troublesome 2 2 Mounting Mount and secure the switch machine on ties according to the layout plans applying to the particular location Adjust the height of the lever stand so that the selector and hand throw levers on M 23A and M 23B machines are held in a horizontal position parallel with the top of the gearbox 2 3 Switch Rod Installation and Adjustment Connect the switch operating rod and adjust the rod nuts at the switch basket to obtain the proper pressure at the switch poi
102. nt Selector clutch adjustment should be checked occasionally When the selector lever is in 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 Figure 3 12 Referring to Figure 3 12 and Figure 3 14 note that the selector clutch yoke has one end supported on and driven by the finger on the selector lever shaft and its other end pivots on eccentric bushings C1 Figure 3 12 held fixed by through bolt G When this bolt is loosened however the eccentric bushings may be rotated to raise or lower the center line for the pivot holes in the yoke arms thus affecting the elevation of the yoke rollers The eccentric bushings have hexagonal heads for application of an adjusting wrench On each eccentric bushing one flat is stenciled N which will be on top when the eccentric is in its mean position The adjacent flat on one side of the N is stenciled and when the eccentric bushings are turned to bring the mark up this will lift the yoke and its rollers The flat on other side of the N is stenciled The two eccentric bushings should be kept turned a like degree or to avoid twisting the yoke Then tighten pivot bolt to hold adjustment 5 24 SM 6263 Rev 7 June 2009
103. nts Nothing is gained by excessive pressure 2 4 Lock Rod Installation and Adjustment With the covers removed and machine at mid stroke apply the lock rods Be sure that the flat plate snow cover is assembled on the track side where applicable when applying the lock rods and that the rods are assembled such that the locking dogs in the lock box will enter the narrow notches first In some instances it may be necessary to invert the lock box to suit the rod notches in this case refer to the instructions in paragraph 2 11 1 Preliminary adjustment should be made by setting the nuts so that the narrow notches are nearly centered on the locking dogs at each end of the stroke This requires that the M 23B machine be operated by power or by turning the friction clutch housing by applying a ratchet wrench to the clutch adjusting nut with the selector SM 6263 Rev 7 June 2009 2 1 2y 3 Installation and Adjustments AnsaldoSTS lever in the MOTOR position and power disconnected The upper narrow notch can be seen directly Index marks are provided on the top surface opposite the notched ends for the lower notch Make final adjustments in accordance with AREMA Signal Section or railroad instructions Figure 2 1 Typical M 3 Machine Application 2 2 SM 6263 Rev 7 June 2009 n AnsaldoSTS Installation and Adjustments f 1 UO
104. ockwise out from under the follower forcing the contacts up While the switch is in transit both the normal and the reverse indication contacts are up engaging the shunting strip S Figures 3 4 and 3 6 to provide a shunt for the indication relay When the machines leave the factory this strip is assembled to connect one normal and one reverse contact but may be reassembled to shunt all four contacts when indication circuits require such arrangement When the machine reaches the end of its stroke the notch in cam P comes on top and thus permits the reverse pair of contacts to close except when prevented by point detection SECTION A A LEGEND Y SS i ac e m K In Si Y P I I E mi E RO A F IDLER PINION GEAR P L INDICATION CONTACTS LEFT NCR i Sas VA a Z 777277 INDICATION CAM SHAFT Figure 3 6 Sectional View of Indication Circuit Controller 3 8 SM 6263 Rev 7 June 2009 5 77 AnsaldoSTS Operation z EO o o lt 5 5 a ui amp 2 552 e o o c lt gt I Sca 5 223 coe m o 9848 SIOVINOO NOILVOIGNI aos 99675 529 S19 V1NOO HOLOW s E 92590 c o gcc 5289 a du 5 6 Eg a 2 5 oa o bez
105. of a bridge rectifier if used should also be temporarily jumpered out To check the friction clutch adjustment apply a temporary jumper across the binding posts of the pick up coil on the overload relay See NOTE and insert an ammeter in the motor circuit as follows Connect negative ammeter lead to binding post on switch machine terminal board and positive ammeter lead to binding post 5 or 10 depending upon switch point position The average peak current taken by motor with clutch slipping should be within 1096 of the nominal value shown in Table 5 2 for the particular motor and gear ratio involved The motor current must be checked in both directions If necessary remove cotter and screw the friction clutch spring adjusting nut Figure 5 2 in or out to obtain desired current After tests are completed remove temporary jumper from overload relay SM 6263 Rev 7 June 2009 5 9 U Shop Maintenance AnsaldoSTS Table 5 2 Adjustment to Slip the Clutch Adjust Clutch to Slip at Amps Motor Gear Ratio 110 VDC 189 1 The motor current listed for gear ratio 189 1 must be checked in both directions and set for a minimum of 14 amps A variance of about 1 to 3 amps may exist due to mechanical alignments and motor characteristics Piece numbers N451160 0504 and 0505 have the clutch set to slip at 14 amps Gray motor machines are shipped from the factory set to slip at 20 amps The clutch may be adjusted
106. oltage 2 11 1 Inverting the Lock Box As explained in Section 3 1 lock box dogs must enter the narrow notches of the lock rod before reaching the wide notch In some cases it may be necessary to invert the lock box to obtain this condition SM 6263 Rev 7 June 2009 2 15 I 3 Installation and Adjustments AnsaldoSTS When inverting the lock box is necessary remove the lock rods and proceed as follows see Figure 3 5 a Place the machine in the end stroke position which brings lock box nearest the motor Note which one of the indication cams N or P has its notch up and that this notch is centered about roller D b Unscrew bolts T which hold the circuit controller to the case Swing the controller upward pivoting it about the edge of the case adjacent to the wire conduit c Turnlock box G upside down taking care that it is replaced properly on the driving studs of the slide bar d Reinstall the circuit controller checking that pinion gear F Figure 3 6 meshes with the rack teeth on the lock box in such manner as to place the indication cam with its notch up and centered about roller D the same as it was before the circuit controller was removed e Fasten the circuit controller in place with bolts T 2 11 2 Shifting the Indication Cams Electric shock or personal injury may occur if motor and indication power is not disconnected before shifting the indication cams Indication cams N and P see Fig
107. on After cleaning carefully check case cover and other structural components for hairline cracks breaks weak points or any other signs of physical damage During disassembly carefully check each part for signs of damage Replace any part found to be defective SM 6263 Rev 7 June 2009 5 1 Shop Maintenance 77 AnsaldoSTS 5 4 Disassembly 5 4 1 Removal of Motor Brushes Refer to Figure 6 1 and Figure 6 2 NOTE When replacing motor brushes both brushes should be replaced For Blue Motor Applications Motors BA 3640 4418 56C BA 3636 4419 56C BA3640 4420 56C with external brush covers Type B Remove motor compartment cover 40 Remove motor brush commutator covers by removing two screws on each side of cover Lift and push to release spring holder Remove motor brush from case Repeat for the other brush b For Gray Motor Applications Motors D 422305X6432 D 42206X6532 and D422307X6632 with brush band cover Type A Remove motor compartment cover 40 Loosen brush commutator cover and slide to allow access to brushes Loosen brush terminal screw and remove brush lead Retract brush spring and remove brush Repeat for other brush 5 4 2 Removal of Motor Refer to Figure 6 1 and Figure 6 2 Remove motor compartment cover 40 Tag and remove wires attached to connections at motor s end closest to conduit outlet Position wiring harness out of the way Remove two 1 2 13 x 2 hex head cap s
108. on Contact Spring D Figure 5 5 Motor Cutout Contacts and Actuator SM 6263 Rev 7 June 2009 5 19 A Shop Maintenance AnsaldoSTS 2 CIRCUIT CONTROLLER COMPARTMENT GERA BOX EYEBOLT L MUST NOT CONTACT EITHER SIDE OF SLOT YOKE B MUST CONTACT BEARING C BEFORE SCREW JAW D CONTACTS BERAING FRAME D OLO G WHEN USED NORMAL RELEASE LEVER 6A2 0087 00 Ye Db Screw Jaw Dune Somin H Bracket S Contact Insulation K s YOKE B MUST REST AGAINST BEARING C ON THIS SIDE bi MESI 17 8 l APPROX SECTION Z Z HAND CRANK HASP OPEN SPRING MUST NOT BE YOKE B MUST REST FULLY COMPRESSED AGAINST BEARING C ADJUST NUTS N ON THIS SIDE AS REQUIRED E iH un 7 2 Er d WHEN FULLY CLOSED WITH HASP HAND CRANK HASP CLOSED IN NOTCH OF STAPLE ADJUST ROD A SO THAT THERE ISA GAP BETWEEN HASP AND GEARBOX WALL 6A2 008800 Figure 5 6 Yoke and Bearing Positions 5 20 SM 6263 Rev 7 June 2009 AT AnsaldoSTS Shop Maintenance b Yoke B stops against the bearing C as shown in section Z
109. or cutout contacts to open the motor circuit and in some cases to control a line circuit The cutout contacts are mounted in the circuit controller compartment and are operated by a spring return push rod projecting into the gearbox This push rod is shifted toward the circuit controller by the action of a cam ledge on the selector clutch yoke engaging an adjustable rocker arm as shown in Figure 3 15 ROCKER ARM MOTOR HAND POSITION POSITION ADJUSTING ROD RETURN SPRING MOTOR CUT OUT CONTACTS A p Figure 3 15 Motor Cutout Contact Assembly M 23A and M 23B Machines 3 7 2 M 23B Mechanism The mechanical difference between M 23A and M 23B mechanisms is the hand throw pinion see Figure 3 16 The single tooth on the hub of the hand throw pinion for the M 23B mechanism is of shorter arc than that for the M 23A thus introducing sufficient lost motion between the pinion and the selector clutch to permit full stroke of the hand throw lever and thus the switch points without moving the slide bar far enough for the locking dogs to engage the lock rods and thereby lock the switch points The travel of the main crank is ample however to lock the switch operating bar against back thrust SM 6263 Rev 7 June 2009 3 21 N Operation 77 AnsaldoSTS BOTTOM VIEW OF HAND b BOTTOM VIEW OF HAND THROW BEVEL PINION THROW BEVEL PINION FOR M 23A MOVEMENT FOR M 23B MOVEMENT Figure 3 16 Hand Throw Beve
110. pecifications Ordinarily readjustment will not be required as long as the assembly remains undisturbed If an adjustment is required it would be best to adjust the machine in the maintenance shop Refer to Section 5 5 6 1 for these procedures 3 4 Point Detector The indication contacts are positively opened by the lock box action and merely permitted to close when the cam notches are aligned unless closure is prevented by point detector action Point detector checks switch point closure separately from the lock rod connection and is used not only to check the switch point when it is first closed but also to detect damage to a switch point caused by dragging equipment or by traffic running through the switch improperly while the machine is in the locked up position The point detector apparatus in this circuit controller is selective like the locking in that the point detector bar must shift to correspond with the switch operating stroke when the machine is reversed It also has a latchout feature that will hold 3 10 SM 6263 Rev 7 June 2009 AND 77 AnsaldoSTS Operation the indication contacts open until reset when the point detector bar is displaced while the machine is in the locked up position The latch is arranged to take advantage of the considerable displacement of the point detector bar which occurs at the time the switch points are being deflected by improperly trailing traffic or by dragging equipment so that the conta
111. plates and take out the small lock screw using the special tool Pc No N173641 to remove the packing gland nut Remove the old packing and clean the shaft and the inside of the clutch housing by washing with a non flammable grease solvent Apply a new felt washer J047335 and oil seal J7900260003 to the housing recess and assemble the packing gland nut Using the spanner end of the special wrench pull down nut only until it is flush with the bottom of the clutch housing Then the locking screw should be inserted and drawn down securely Coat rubbing surfaces of packing rings with gearbox lubricant Assemble housing to the shaft Clean lubricant from shaft surface inside the clutch space Old fabric discs should be discarded and replaced Old clutch plates should be thoroughly cleaned in a non flammable grease solvent to remove any accumulation of lubricant and then reassembled as shown It will be noted that a fabric disc goes in the bottom of the housing and the first metallic disc is one with teeth engaging the shaft 5 5 5 2 Assembly of Friction Clutch Refer to Figure 5 1 Install gasket 1 in gearbox opening Install plate 2 with two 1 4 20 x 3 4 hex head cap screws 13 Align tubular neck of clutch assembly and worm shaft 12 Insert tubular neck of clutch assembly partially over worm shaft and through gearbox bushing Align three finger end of tubular neck with matching slots in clutch gear hub Push tubular neck into gear hub
112. pposite position and finally the main crank holds the switch operating bar while driving the slide bar to its full stroke position engaging the top locking dog in the corresponding lock rod notch The manner in which the crank imparts these motions can be understood by referring to Figure 3 1 Figure 3 2 and Figure 3 3 The main crank is designated X the switch operating bar Y and the slide bar Z Assuming that Figure 3 2 and Figure 3 3 show the Normal position a reverse movement is started by a clockwise rotation of main crank X Lug x on top of main crank X acting against roller z on slide bar Z effects the unlocking of the lock rod by causing slide bar Z to move to the left one half of its stroke Meanwhile roller x on the underside of main crank X is moved through an arc of 40 degrees in the radial portion of groove y in switch operating bar Y thus freeing the bar for the reverse stroke During the next 140 degrees of rotation of main crank X roller x engages the straight reverse operating face of groove y and moves the switch operating bar Y to the reverse position Figure 3 2 and Figure 3 3 show the relative mid stroke positions of switch operating bar Y and slide bar Z crank X is still rotating clockwise but is not transmitting motion to slide bar Z as lug x has become disengaged from roller z Surfaces v and v of slide bar Z are radial to the center of the shaft and prevent the slide bar from moving The full reverse position
113. rily for new installations Figure 2 7 five wire control and Figure 2 8 three wire control similarly show internal view A and control wiring views B and C for high voltage machines For ALSTOM GRS replacement machines two wire control refer to the wiring diagrams in Section 7 The circuit controller indication cams are shown for a switch having the right hand point normally closed and in Normal position There is no difference due to the side of the track on which the machine is placed Figure 2 5 through Figure 2 8 views B and C are typical circuits for the control of switch machines using the standard PN 150SO the PN 150BM and the PP 151 plug in relays These typical circuits show wiring of the relays which corresponds to the internal wiring diagrams for standard DC switch machines as applied to single switches SM 6263 Rev 7 June 2009 2 7 n Installation and Adjustments AnsaldoSTS A INTERNAL WIRING CIRCUIT CONTROLLER CONTROLLER MOTOR DU arn MAIN T N TERMINAL BOARD Oy Oo a 3 3 G 2SEL 9 4 QD CONTACTS 9 8 2 CONTROLLED BY 2 9 paro uh 3 7 D I L 50 499 4 12 49 SHUNTING Q 2 2 0 9 s 3 13 2 13 9 COMET 0118 22 16 24 WHEN USED 29 a 9 15 4 M DIRECTION OF NEXT ROTATION NOTE NUMBER IN CIRCLE REPRESENTS NUMBER OF TERMINAL NUMBER NOT IN CIRCLE SHOWS NUMBER OF TERMINAL TO WHICH OTHER END OF WIRE IS CONNECTED
114. roperly relative to the other gear centers The motor can be removed by taking out the two bolts in the motor bracket at the commutator end For detail information on the motor see paragraph 3 8 The reduction gears are assembled on shafts supported in Oilite bearings The shafts are held in place endwise by the shaft end plate which is slotted to fit over a neck in each shaft To remove these shafts to change out the reduction gears it is necessary to first shift the motor out of the way see previous paragraph The clutch gear which is the final spur gear has an Oilite bushing to support it on the worm shaft This gear is connected to the worm shaft through the friction clutch as will be described The worm shaft meshes with the worm gear on the main crankshaft and 1 supported at the end adjacent to the controller by a double row ball bearing that takes both radial load and end thrust It also is supported by a single row ball bearing in the wall between the worm gear compartment and the spur gear compartment Both ball bearings are lubricated by the worm gear lubricant A cap on the outside seals the outer side of the double row ball bearing and an oil seal pressed into the opening is provided on the spur gear side of the single row ball bearing SM 6263 Rev 7 June 2009 3 15 3 16 A Operation 77 AnsaldoSTS Top View 131 REDUCTION GEAR LEGEND For Figs 3 11 amp 3 12 A1 BOLT A2 BOLT A3
115. s between the point detector cranks With wire harness within the clamps reinstall the four wire clamps with four 5 16 x 1 5 8 machine screws and four 5 16 lock washers Refer to tags and reattach harness wires to correct circuit controller terminals and heater connections Tighten all screws securely and be sure the gearing on the circuit controller meshes properly with the crank teeth on the movement lock box See that the circuit controller shaft assembly is in the angular position agreeing with that shown in Section Y Y of Figure 6 5 checking specifically the relation shown in the schematic diagram for setting of segments for contacts 24 25 and 26 27 This should place the cam block Item 57 of main shaft gear Item 56 in the position shown The next move should rotate the cam block away from rather than into the pinion gear Item 59 Install at least three of the circuit controller frame hold down bolts but do not tighten By use of the hand crank or hand throw lever operate the movement slowly checking that the cam block moves in the proper direction Before tightening circuit controller frame hold down bolts check that full stroke controller shaft rotation gives symmetrical contact relationship at both ends of the stroke Shift clear tooth engagement if necessary to obtain this condition Install and tighten all hold down bolts 5 5 6 1 Motor Control Contacts The motor control contacts are set at the factory to ensure that the switc
116. selector lever and lever interlock must be reassembled 180 from original position on shaft as follows 1 Remove hex nut and washers from end of selector lever shaft and slide selector lever and lever support K from the shaft Be careful not to lose steel ball in lever support NOTE If stop screw is used in hub of hand throw lever it will be necessary to remove this lever also and interchange stop screw and cap screw refer to Figure 2 9 Replace hand throw lever and fasten in place with clamping bolt 2 Reassemble lever support K with hole for the ball on motor side of shaft Insert steel ball and reassemble selector lever on shaft so that lever will be 180 degrees from its original position Stop screw if used may require positioning hand throw lever to align recess with hole in lever support so that ball will not interfere when selector lever is applied Replace hex nut and washers on end of shaft to hold selector lever in place and fasten lever support K with the two 1 2 13 bolts A3 which also secure the bottom of the lever shaft bearing 3 Operate selector lever to motor position i e toward motor end of machine and check that it moves yoke N down 4 Interchange MOTOR and HAND nameplates on selector lever to correspond with these lever positions The MOTOR and HAND nameplates must be interchanged on the selector lever to correspond with the lever positions to avoid possible physical injury
117. slots until neck hub is in clutch gear hub Push tubular neck into gear hub slots until neck hub is solidly engaged Install the following items on the worm shaft a Insert clutch disc until it sits against inner wall of clutch housing 5 8 SM 6263 Rev 7 June 2009 A 77 AnsaldoSTS Shop Maintenance b Insert clutch plate in groove on worm shaft until it mates with clutch disc c Insert another clutch disc d Insert another clutch plate e Repeat steps c and d for three remaining clutch discs and two remaining clutch plates f Insert clutch end plate on worm shaft Slide clutch spring over worm shaft until it rests against clutch end plate Install clutch adjusting nut on worm shaft Tighten clutch adjusting nut in accordance with friction clutch adjustment procedures Recheck this adjustment after a brief wearing in period 5 5 5 3 Friction Clutch Adjustment Friction clutch adjustment should be checked to be sure the clutch slips at a torque which will protect the mechanism from shock yet adequate to carry usual operating loads Also for proper operation of the overload relay the clutch must be maintained to slip at a current value above the minimum current rating of the relay or no protection will be obtained NOTE In addition to a temporary jumper across the binding post of the pick up coil on the overload relay called for in the maintenance and adjustment section of this manual all 6 1 4 amps Fusetrons on the 110 VDC side
118. sm M 23A and M 23B c Circuit controller compartments This compartment contains the circuit controller locking features point detector device and a separate set of motor cutout contacts which open the motor circuit and may also control a line circuit whenever the hand crank is inserted in the M 3 machine or the selector lever is operated out of its motor position in the M 23A and M 23B machines In addition to the elements just mentioned a slide bar runs lengthwise in the base of the machine It is driven by the main crank and operates the lock box in the circuit controller compartment Perpendicular to the mechanism and beneath the slide bar is a switch operating bar which also is driven by the main crank and to which the switch operating rod is connected see Figure 3 1 The point detector rod and lock rods operated by connections to the switch points are supported in the circuit controller compartment Switch operation switch locking and circuit controller operation are all performed by the vertical main crank in the gearbox The main crank is driven either by the motor or by the hand operation facilities Refer to Section 3 for detailed operation of the switch machine 1 2 SM 6263 Rev 7 June 2009 ex 77 AnsaldoSTS 1 4 Specifications 1 4 1 Physical Characteristics Table 1 1 Physical Characteristics M 3 M 23A M 23B Length 63 1 2 in 63 1 2 in Width Height 10 1 4 in Weight 810 Ib 860 Ib 1 4 2
119. t the motor terminals should be measured with the clutch slipping Refer to Section 5 5 5 3 for information on the adjustment to slip the clutch 3 22 SM 6263 Rev 7 June 2009 AnsaldoSTS Operation 3 8 2 Overload Protection The standard plug in type relay for the overload protection of DC switch machines is the Style PN 150SO relay This relay is used in conjunction with the style PN 150BM switch control relay and the style PP 151 magnetic stick relay for overload and short circuit protection Where shelf mounting relays are used overload protection may be obtained for the DC machines by use of the OR 11 overload relay and the DP 25 relay for switch control In ordering a switch overload relay the current at which the clutch is set to slip or the gear ratio of the machine and the type of the machine with Which it is to be used should be specified The gear ratio is stamped on the switch machine name plate The thermal resistors of these relays are selected to give proper operation for the value of current at which the clutch slips with overload 3 9 Heaters Fifteen watt heaters are available for use in the circuit controller and motor compartments The heaters operate on 24 VDC 115 VAC VDC or dual element 115 230 VAC VDC power The heater for the controller compartment mounts at the end of the controller opposite the wire inlet as shown in Figure 3 17 It is held in place by the same four screws that fasten the
120. thout self restoring latch out block SM 6263 Rev 7 June 2009 6 1 5 Configuration Guide and Parts List AnsaldoSTS Table 6 2 M 3 Switch Machine Assemblies Part Number Configuration Control Right Hand Left Hand Ref Gear Ratio Speed Wiring N451160 0301 N451160 0302 C L 5 Wire N451160 0317 N451160 0318 110 0 1891 4 5 sec 3Wire 451160 0329 N451160 0328 C D J R 110 VDC 189 1 ALSTOM GRS Replacement Machines NAS TOO Dos T 8251160039 2 Wire Control Refer to Section 7 N451160 0333 N451160 0332 C D J P 110 VDC 360 1 N451160 0335 N451160 0334 C D J P 110 VDC 360 1 N451160 0337 N451160 0336 C D J P S _ 110 VDC 360 1 ALSTOM GRS Replacement Machines SSS MK SS 0555 2 Wire Control Refer to Section 7 C D J 6 5 J C 4 N451160 4006 451160 4005 C D J 110 VD 189 1 6 2 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List Table 6 3 M 23A Switch Machine Assemblies Part Number Configuration Control Right Hand Left Hand Ref Wiring N451160 0502 N451160 0501 5 Wire 451160 0503 51160 0506 1 20VDC 5281 26sec 5Wire 451160 0507 51160 0508 1 20VDC 3601 15sec 5Wire N451160 0509 20VDC 360 1 15sec 5Wire 451160 0512 51160 0513 20VDC 5281 26sec 5Wire 451160 0514 10 0 1891 45sec 5Wire
121. til it is engaged with the other elements as covered by Note A Figure 1 2 3 18 SM 6263 Rev 7 June 2009 EN 77 AnsaldoSTS Operation NOTE In as much as the switch operating mechanism may remain in engagement with the motor rather than with the hand throw lever when the selector is operated to HAND position it is necessary to actually operate the switch by the hand throw lever to assure that the machine is in the hand operation position 3 7 1 Operation By Selector Lever The selector clutch assembly is shifted up or down by 180 degrees of rotation of the selector lever the inner crank finger of which swings the selector clutch yoke up or down This yoke has rollers on each side engaging the upper and lower spring cups of the selector clutch assembly The selector clutch assembly as shown in Figure 3 14 has a spool shaped core made in two parts which are screwed together and are held from becoming unscrewed in service by the splines in both portions The upper part or clutch for hand operation has a single tooth on top for engaging the hand throw pinion which requires strict agreement of the hand throw lever position with the position of the switch when engaged The lower part has five teeth for engagement with the worm gear The upper and lower parts are separable only when the assembly is removed from the splined shaft this arrangement being used to permit assembly of the spring and two spring cups The spring cups
122. tor 0 enne enn 3 19 3 7 2 M 23B Mecharism 2 iint eere d ee a sia Perte 3 21 3 9 MOTOR um ee tete emp tem out he mes 3 22 3 8 1 22 eee idee c ep 3 22 3 8 2 Overload Protection s a eis Ice AA cach apte ei ape ene ge die 3 23 3 9 H68161S iE o a GENS IARE de 3 23 SM 6263 Rev 7 June 2009 iii n Table of Contents AnsaldoSTS 4 FIELD MAINTENANCE u MEE 4 1 4 1 Preventive Maintenance 4 1 ATA sINSPOCHON ss sua AGE TEG ee 4 1 4 1 2 SwitehLayout sese nd arn tete eh aie 4 2 4 1 3 Switch Machine 4 2 e o ee rr er etre i eda Fr 4 3 4 2 1 Equipment Materials 4 4 42 2 Procedure e et e d da e oe ic pase 4 4 413 I bubricatuoros ooo teet Oei e iro e se E 4 4 4 4 Switch Machine Performance 4 4 4 5 Corrective Maintenances a telnet aree Sy iaa 4 4 4 5 1 Friction Clutch eene nennen rnnt enne 4 5 4 5 2 Switch Machine to Switch Adjustments sse 4 5 4 5 3 Motor Control Contacts 4 5 4 5 4 Indication Contacts Adjustment
123. uit controller compartment Incorporated CRS 01220 and MN 05 001 into Section 5 7 2 1 Corrected the adjustment gap for the motor cutout contacts Incorporated CRS01497 added circuit controller part number Incorporated 139712 395 Updated Section 7 Alstom GRS Replacement Machines 7 June 2009 Incorporated ECO 139712 353A Updated parts list Incorporated MR 09 02 updated Section 5 7 2 Updated Section 7 Alstom GRS Replacement Machines Incorporated ECO EM 3188A Revisions were not numbered at the time these were issued ii SM 6263 Rev 7 June 2009 A 77 AnsaldoSTS Table of Contents Table of Contents 1 GENERAL INFORMATION u eee U rese 1 1 US EE Ini 1 1 1 2 DeSonptlON E 1 1 1 9 Operating MECHANISM s i ee A o rad eda e Sr aa AS 1 2 1 4 Specifications eun 1 3 141 Physical Characteristics 1 1 sian e nt ds 1 3 1 4 2 Operating Characteristics nnns 1 3 1 4 3 Electrical Data ECA EDA LEENA EA 1 3 2 INSTALLATION AND ADJUSTMENTS U U u u u u u u 2 1 222 General Information AO AIA EEU AL 2 1 2222 2 1 2 3 Switch Rod Installation and Adjustment sss 2 1 2 4 Lock Rod Installation and
124. ure 3 5 are arranged so that either cam can have its notch up when the slide bar is at either end of its stroke This permits standardized wiring by always having the indication contacts on the left side of the circuit controller indicate Normal regardless of which end of the slide bar and lock box stroke is designated Normal Each cam is driven by a stud in the side of the gear and has two slots so that it can be engaged with its corresponding stud in either of two positions The cams are held engaged with their respective studs by spring force and an 8 32 Allen Head Set Screw adjacent to slots that is tightened against the gear hub after adjustments have been made To shift the cams from one position to the other loosen the 8 32 Allen Head Set Screw adjacent to the slots then carefully to avoid distortion of contact springs insert two screw drivers between the cam and the gear Force the cam away from the gear against the force of its coil spring and then rotate the cam to the alternate position until it snaps in place see Figure 3 7 Tighten set screws in place Repeat this process for the other cam The two cams must be shifted individually 2 16 SM 6263 Rev 7 June 2009 AND y AnsaldoSTS Installation and Adjustments 2 11 3 Converting Between High and Low Voltage Conversion between high and low voltage operation involves the gear ratio motor and wiring The desired gear ratio may be obtained by changing the reduction
125. ver Shaft M286618 Selector Lever Shaft M286619 ine 3 Shaft M149700 First Reduction Gear 360 1 Gear Ratio M286577 First Reduction Gear 528 1 Gear Ratio M286579 189 9 0 2 M286576 M286578 2 io A M286580 M286591 M286592 M286587 J048925 M169502 M174967 J475187 6 J047783 J048057 J048613 M169503 N302735 u 0 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 N286672 4 N286622 4 M217537 4 M217538 4 M261981 4 M261980 4 J050251 4 J475187 4 N286603 4 M286596 4 M286614 4 M286584 5 Cutout Rod Adjuster Link M286613 5 M286595 5 M286585 5 M274598 5 M274603 5 M292426 5 M274602 5 N288677 5 Bushing Oilite J079694 6 9 4 5 6 7 8 9 0 1 2 3 4 5 6 a 7 8 9 a 1 2 3 4 5 6 a 7 8 9 a 0 1 2 3 4 5 6 7 8 6 20 SM 6263 Rev 7 June 2009 lt AnsaldoSTS Configuration Guide and Parts List Description Part Number Lubricating Fitting 1 8 P T J039137 60 PlateWasher7 8 PlainS Plated 7 1404758 63b 64 64a 65 65 67 67 70 Ball Bearing Double Row 71 72 73 74 75 75a 76 76a 77 M292411 78 M253753 79 M218627 J067035 81 J790008 82 J790007 83 J790004 84 85 87 Care must be taken when ordering these items as some M 23A and M 23B machines were furnished with 10 spline main cranks and repair parts must be ordered to suit SM 6263 Rev 7 June 2009 6 21 N w Configuration Guide and Parts List AnsaldoST
126. vides two parallel circuit paths one through direct contact of opposing spring fingers F1 and F2 Figure 3 7 and the other through finger F1 the conducting segment and finger F3 The circuit through the segment opens last as the notch passes under the V end of the finger F1 finger F2 being stopped first before the V end clears the segment altogether This arrangement protects the direct finger contact from having to open the motor circuit under normal conditions yet ensures a circuit in case the segment should become coated with frost Referring to Figure 3 7 it will be noted that each motor control segment is nested on the tapered hub of its insulating bushings The cone engagement has teeth in both elements that prevent the segment from rotating relative to the shaft when the shaft end nuts are pulled up but that permit the segment to be shifted angularly around the shaft in 4 degree steps when the shaft end nuts are backed off These segments are set in the factory to provide approximately 1 4 opening between the segment ring and the V end of the contact finger Fl Sect Y Y and 7 7 and approximately 1 8 margin against opening under finger F3 Sect W W and X X when the machine is in its full stroke position operated as far as it will go by rotating the friction clutch by hand while in MOTOR position The motor control contacts are set at the factory to ensure that the switch machine is locked in accordance with AREMA s
127. witch Machine Gear Box Parts Location 6 18 SM 6263 Rev 7 June 2009 5 4 AnsaldoSTS Configuration Guide and Parts List 6 4 M 23A and M 23B Switch Machine Gear Box Parts List Table 6 8 contains the parts list for the gear boxes used in the switch machines listed in Table 6 3 M 23A and Table 6 4 M 23B Figure 6 4 shows a location diagram for the listed parts Table 6 8 M 23A and M 23B Gear Box Parts List Description Part Number Gear Box Complete 23 Gear Box Complete M 23B 1 5 2 2 222 EN 2 Gearbox Includes Bushings amp Oil Seals N286623 3 TopBearing 7 2749 4 Worm Shaft M286612 5 Friction Clutch Housing 51272 6 Friction Clutch End Plate 6450 Mi46575 7 Fri 8 9 10 12 13 FetWahe 5 0 0 i7 BearngCap a 2 27456 18 Clutch Gear Includes Bushing Ref 88 8653 19 Spacer 286593_ 20 WormGear M286820 21 Hand Throw Bevel Pinion M 28A Machines 286616 21A Hand ThrowBevelPinion 23 Machines 266 7 Ref 1 2 3 4 5 7 10 11 12 13 14 16 17 18 19 20 21 21A SM 6263 Rev 7 June 2009 6 19 5 E Configuration Guide and Parts List AnsaldoSTS o 3 Description Part Number 22 Hand Throw Bevel Gear 286611 3 Main Crank 5 Spline M302731 A Main Crank 10 Spline M286608 Hand Throw Le
128. y releasing the hand throw lever While the hand throw lever is at any position between the ends of its stroke the ball is held in the recess in the selector lever hub and thereby locks the selector lever The hand throw lever hub has two ball recesses 180 apart so that at either end of the lever stroke one of the recesses will be aligned with the ball to unlock the selector lever If it is desired to make it compulsory that the hand throw lever be in the Normal position before allowing the selector lever to be operated one of the ball recesses in the hand throw lever must be plugged by the use of stop screw Pc No 14287186 as indicated in Figure 2 9 When used the stop screw must be applied to a particular recess in the hand throw lever hub as follows With the hand throw lever in the Normal position the stop screw must be in the recess on the side of the shaft opposite to the side the selector lever is on when in its MOTOR position see Figure 2 9 The lever support can be assembled with the hole for the ball on either side of the lever shaft center However it must be assembled so that the hole for the ball is on the same side of the shaft as the selector lever is in for MOTOR position see Figure 2 9 As previously mentioned the selector lever can be assembled on the square end of its shaft in either of two positions 180 apart so as to have the MOTOR position of the lever either toward the motor compartment or toward the circuit

SM-6263 - Ansaldo STS

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