000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006 SM 5A1.0002 Model 95 Electronic Gate Controller Retrofit Kit Installation © Copyright 2010 Ansaldo STS USA, Inc. SM 5A1.0002, Rev.
Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA, Inc. (formerly known as Union Switch & 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.
Revision History Revision History REV. 1 DATE March 2010 NATURE OF REVISION Initial Release Copyright© 2010, Ansaldo STS USA, Inc. 1000 Technology Drive, Pittsburgh, PA USA 15219-3120 645 Russell Street, Batesburg, SC 29006 www.ansaldo-sts.com All rights reserved. ii SM 5A1.0002, Rev.
Table of Contents Table of Contents 1. 2. 3. 4. GENERAL INFORMATION ...............................................................................................................1-1 1.1. Parts List ...................................................................................................................................1-1 1.2. Safety ........................................................................................................................................
Table of Contents List of Figures Figure 2-1. Circuit Wiring Diagram .....................................................................................................2-4 Figure 2-2. Electrical Bracket Assembly.............................................................................................2-5 Figure 2-3. Motor Control Relay (MCR) Mounting..............................................................................2-6 Figure 2-4.
General Information 1. GENERAL INFORMATION This document describes the removal of the Motor Control Relay (MCR) control circuitry and the installation of the Electronic Gate Controller for the Model 95 Gate Mechanism. The Electronic Gate Controller Upgrade Kit improves the reliability of the Model 95 gate mechanism by removing the standard non-vital motor control relay (MCR) and replacing it and other discrete components with a completely electronic circuit.
General Information 1-2 SM 5A1.0002, Rev.
Removal of Existing Controller 2. REMOVAL OF EXISTING CONTROLLER Refer to Figure 2-1 or to SM 6495 for the existing wiring diagram. 2.1. Existing Control Circuitry Removal Proceed as follows to remove the existing control circuitry from the gate mechanism: 1. Remove the gate mechanism from service and render it in a safe condition for maintenance. 2. Disconnect power from the gate by loosening the gold nut on Terminal 5B. 3. Remove the B12 supply wire from Terminal 2C and insulate the end of the wire. 4.
2-4 - C11/ A11 (H2) (H4) (H3) - B11 C8/ A8 SEE NOTE 4. MOTOR HC (BRAKE) MCR (B4) (F4) (B3) (B2) (F2) A1 + C1 C12/ A12 C10/ A10 B12 C9/ A9 C7/ A7 UNION SWITCH & SIGNAL 645 RUSSELL ST.
Removal of Existing Controller 10. Remove the two ¼"- 20 screws that secure the MCR (Figure 2-3). 11. Remove the MCR. The MCR will not be reused. CIRCUIT BREAKER LIMIT RESISTOR A A C C 5A1.0019.00 SNUB RESISTOR Figure 2-2. Electrical Bracket Assembly SM 5A1.0002, Rev.
Removal of Existing Controller Figure 2-3. Motor Control Relay (MCR) Mounting 2.2. Removal of Power Down Module Model 95 Gate mechanisms built prior to September 1, 2003 have the power down module located underneath the cam contact assembly (Figure 2-4). Gate mechanisms built after September 1, 2003 have the power down module circuit board connected directly to the cam contact terminals (Figure 2-5). 2.2.1.
Removal of Existing Controller Figure 2-4. Prior to September 1, 2003 Power Down Module Location 2.2.2. Removal Procedure for Gate Mechanisms Built After September 1, 2003 Proceeds as follows to remove the power down module: 1. Disconnect the wire at Terminal 5B. 2. Remove the three hex nuts that hold the potted module board to the cam contact on the electrical assembly at Terminals 1C, 2C, and 3C. 3. Remove the power down module. It will not be reused.
Removal of Existing Controller Figure 2-5. After September 1, 2003 Power Down Module Location 2.3. Removal of the Maintenance Switch assembly 1. Disconnect the following wires for the maintenance switch assembly: a. Terminal 6B (two leads) b. Terminal 2C c. R2 from the SNUB resistor d. Terminal T4 e. Terminal T6 f. Terminal T7 2. Remove the two 1/4"-20 nuts and bolts from the side of the electrical assembly bracket (Figure 2-6). 3. The maintenance switch assembly it is not reused. 2-8 SM 5A1.0002, Rev.
Removal of Existing Controller Figure 2-6. Maintenance Switch Assembly SM 5A1.0002, Rev.
Removal of Existing Controller 2.4. Gate Light Fuse Block Assembly 1. If the gate mechanism is equipped with a gate fuse block assembly (part number X46700039) (Figure 2-7), remove the wires from Terminals T1 and T3 for the older version terminal block or Terminals (T7) and (T5) for the newer version terminal block. Newer versions of the gate mechanisms have the terminals labeled as indicated by the parenthesis in Figure 2-7. 2. Remove the two 7/16" hex nuts and lock washers. Remove the fuse bracket.
Installation of Electronic Controller 3. INSTALLATION OF ELECTRONIC CONTROLLER There are two nomenclatures for the terminal blocks. The older version uses the top three terminals for the gate arm lights. The newer version uses the three-post terminal block horizontally mounted under the Snub resistor for the gate arm lights. Wire the new controller per the configuration labeled Terminal Layout Version 2 as shown in Figure 3-1. 1.
Installation of Electronic Controller 5A1.0029.00 Figure 3-2. Electronic Gate Controller Wiring Diagram 3-2 SM 5A1.0002, Rev.
Installation of Electronic Controller 2. Move the Red motor wire from Terminal T7 to Terminal T4. 3. Move the wires from Terminals 4B and 1B to Terminals T6 and T7. 4. Connect the 4-wire harness as follows. a. Connect the wire tagged W3 (Motor +) to Terminal T4. b. Connect the wire tagged W4 (Motor -) to Terminal T5. c. The wire tagged W1 (B12) to Terminal 2C. d. The wire tagged W2 (N12) to Terminal 4B. 3.3.
Installation of Electronic Controller 3. Plug the 9 terminal plug from the controller into the 9 wire harness plug. Figure 3-3. Controller Mounting Locations 3-4 SM 5A1.0002, Rev.
Installation of Electronic Controller Figure 3-4. Controller Installation 3.4.1. Fuse Bracket Installation If the gate mechanism is equipped with a gate arm fuse bracket (Figure 3-5 and Figure 3-6), install the fuse bracket in the bottom front of the controller using the two ¼" - 20 x 3/8" screws and the two lock washers that are supplied with the kit. Refer to Figure 3-2 and proceed as follows to wire the fuse bracket: 1.
Installation of Electronic Controller 5. The wire on Terminal T2 remains unchanged. Figure 3-5. Gate Arm Light Fuse Bracket Figure 3-6. Installed Assembly 3.5. Tests After the electronic gate controller is installed, the gate must be tested for proper operation. After the tests are complete and the gate mechanism is functioning properly, return the gate mechanism to service following all the railroad’s requirements for servicing crossing gate mechanisms. 3-6 SM 5A1.0002, Rev.
Installation of Electronic Controller Refer to ASTS USA Service Manual 5A1.0001 for maintenance instructions for the electronic gate mechanism. 3.5.1. Gate Mechanism Test Proceed as follows to test the gate mechanism: 1. Restore power to the gate mechanism. The gate should return to the vertical position. 2. Put the maintenance switch in the NORMAL position. 3. Push and hold the red TEST MODE pushbutton and observe the LED display. 4. The BRAKE LED should extinguish and the DOWN LED should illuminate. 5.
Installation of Electronic Controller 4. Release the MAINTENANCE pushbutton and return the toggle switch to the normal position. 5. Connect the Motor (+) wire to Terminal 4. 3.5.3. Gate Arm Fuse Wiring Test If the fuse is installed, test the gate arm fuse wiring as follows: 1. Power the gate mechanism so that the gate arm lights are lit. 2. Remove Fuse 1 from the fuse holder. The tip light and the light nearest the mast should go out. 3. Remove Fuse 2 from the fuse holder.
RAIL Team and Technical Support 4. 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@ansaldo-sts.us. SM 5A1.0002, Rev.
RAIL Team and Technical Support End of Manual 4-2 SM 5A1.0002, Rev.
