645 Russell Street Batesburg, SC 29006 Service Manual 7080 Transit Color Light Signal (6-3/8 Outer Lens Diameter) Installation, Operation and Maintenance November, 997 997, Union Switch & Signal Inc. Printed in U.S.A. An Ansaldo Signal Company
TABLE OF CONTENTS I. General Information...-. Introduction...-.2 Description...-.3 R.A.I.L. Team & Technical Support...-4 II. Installation...2-2. Mounting...2-2- Alignment...2-2- Lens Orientation...2- III. Maintenance...3-3. General...3-3-2 Cleaning...3-3.3 Lens Unit Replacement...3-3.4 Lens Replacement...3-3.5 Lamp Bracket Replacement...3-2 3.6 Lamp Replacement...3-2 3-7 Case Lubrication...3-2 Appendix A - Parts Lists and Diagrams...A- List of Figures Figure - Transit Style Single Aspect Unit...- Figure -2 Transit Style Three Aspect Assembly Back, Front and Side View...-2 Figure 2- Mounting Examples...2- Figure 2-2 Lens Orientation...2-2 Figure 3- Transit Style Signal Case With Lens Unit...3-2 i
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GENERAL INFORMATION. Introduction This manual covers the transit color light assemblies manufactured by Union Switch & Signal Inc. Because of the wide range of signal light configurations, it is not practical to cover each assembly in detail. The information contained in this manual covers the various configurations, mounting, and alignment. Should specific information pertaining to the particular color light be required, please contact the R.A.I.L. Team at Union Switch & Signal Inc..2 Description General Union Switch & Signal Inc. provides two styles of transit signals. Each signal type has mounting for the optional transformer, resistor, hood, and background. The lens unit options are a phanscreen, deflecting lens, or spreadlight lens. The lamp assembly has either one or two lamps, with the two lamp style placing the lamps either side-by-side or front-toback. Single aspect unit The single aspect transit color light signal unit consists of a weatherproof aluminum case with rear hinged door. These units are designed to be used individually or stacked with other units to provide the required indications. Figure -. Transit Style Single Aspect Unit -
GENERAL INFORMATION Three aspect unit The three aspect unit is designed to be used alone or in conjunction with the single aspect unit. When used alone, the three aspect unit can also display two or one aspects by use of blanking plates. Below the bottom lens opening is a mounting area for either an enamelled or illuminated number plate. When neither is required, a blanking plate is provided. Figure -2. Transit Style Three Aspect Assembly Back, Side and Front Views (configured for wall mounted application) -2
GENERAL INFORMATION Door The door used on each signal type totally encloses the rear of the signal case. Each door has a ventilator for preventing condensation and can be padlocked to the case. A backlight can be installed in the door. Lens assembly Each lens assembly consists of the lens housing with a 5-/2 inch diameter inner color lens and a 6-3/8 inch clear outer lens. Bolted to the lens housing is the lamp bracket. This complete lens assembly is preset in the factory and is not designed to be refocused in the field. The combination of the inner and outer lenses concentrates the light into a focused beam. Optional outer lenses can also deflect or spread the light to allow for specific applications. A deflecting lens angles a portion of the light at a particular point. A spreadlight lens can spread the entire light beam. Lamp bracket Three different lamp bracket styles are used. The two styles used for aspect illumination are the bracket using one lamp and the bracket using two lamps. The one lamp style places the lamp filament at the focal point of the lens. The two lamp bracket locates the lamps front-to-back with respect to the lens. The front lamp is placed at the focal point and is wired in parallel with the back lamp allowing both lamps to burn simultaneously. When one lamp burns out, the second lamp will provide the light source at reduced intensity. The Transit style signals use either the one lamp style bracket or the two lamp back-to-back style bracket. For number plate illumination, the third style of lamp bracket is used. This style utilizes two lamps, but places them side-by-side. Since focusing is not required, this provides the best light output for a flat number plate. Deflecting lens There are two types of deflecting lenses. These are the deflecting cover glass and the deflecting close-up prism lens. The deflecting cover glass must be used when additional spread of the light beam is required to properly signal curved track. This type of lens deflects part of the beam to one side of the horizontal centerline. An arrow on the lens indicates in which direction the deflection occurs. The 0 degree deflecting lens is used on moderately curved track and the 20 degree deflecting lens is used on greater track curvature (greater than.5 degree curvature). The deflecting close-up prism lens is typically used in restricted speed areas or when the motor car stops adjacent to the signal. In either application, the engineman, at some point, will move out of the visiblity of the main beam by becoming adjacent to the signal unit, but is still required to observe the indication. The deflected beam is aimed at the position of the engineman so as to allow observance of the indication from a close proximity to the signal. The direction and angle of the deflection is marked on the lens. For orientation procedures, refer to section 2.3. -3
GENERAL INFORMATION Spreadlight lens The spreadlight lens is used for applications covering very great track curvature (over 4 degrees). This lens spreads the beam equally to both sides of the horizontal centerline of the signal. For example, the 30 degree spreadlight lens spreads a beam of light to 5 degrees of each side of the horizontal centerline. Due to the spreading of the entire beam, the intensity is greatly reduced. The spreadlight lens should only be used for short range indication. For orientation procedures, refer to Section 2.3. NOTE The brightness, or intensity, of the signal indication, as well as the range, depends on the beam candle power. The intensity is much lower when a deflecting or spreadlight lens is used. To avoid unnecessary reduction in intensity, use only that deflection or spread that adequately covers the curve..3 R.A.I.L. TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link (R.A.I.L.) Team is comprised of a group of experienced product and application engineers ready to assist and resolve any technical issues concerning any US&S product. Any questions regarding the contents of this Service Manual can be answered by contacting the R.A.I.L. Team toll free at -800-652-7276 or via Internet e-mail at: railteam@switch.com. -4
INSTALLATION 2. Mounting All signal styles can be mounted on a mast, bridge, wall, or cantilever. Mast mounted signals are either top of mast or front of mast mounted and can be provided with steps, ladder, or ladder and platform. Mounting Examples are shown in Figure 2-. Mast Mounting Detail Wall Mounting Bracket Mast with Ladder Figure 2-. Mounting Examples 2.2 Alignment All signal mounting configurations, except wall, have horizontal adjustments. The brackets for wall mounted signals do not have adjustments. For proper alignment, the horizontal adjustment must be performed first. Horizontal point of alignment is determined by track geometry and line of sight. 2.3 Lens Orientation To properly orient deflecting or spreadlight lenses, perform the following steps after the horizontal and vertical alignment of the signal has been completed. See Figure 2-2 for examples. a. From the front of the signal, loosen the screws attaching the lens ring to the housing. b. Rotate the outer lens for proper orientation of the spread or deflection. c. Tighten the lens ring screws securing the outer lens. d. Clean the outer surface of the lens. 2-
INSTALLATION Outer Lens Assembled to Give Vertical Spread Facing Rear View, showing Deflecting Unit for Deflecting Light Downward Outer Lens Assembled to Give Deflection to the Right Facing Rear, Showing Deflecting Unit for Deflecting Light Upward Facing Rear, Showing Deflecting Unit for Deflecting Light Horizontally to Left Outer Lens Assembled to Give Horizontal Spread Figure 2-2. Lens Orientation 2-2
MAINTENANCE 3. General Maintenance primarily consists of maintaining the lens unit and replacing burned out lamps. 3.2 Cleaning The front and back surfaces of both the inner and outer lenses should be cleaned with a Railroad approved glass cleaner, using a soft, nonabrasive, cloth or paper towel. The exterior and interior of the case may be cleaned with a soft dry cloth, paper towel or brush. 3.3 Lens Unit Replacement The lens units are complete assemblies consisting of the inner and outer lens and the lamp bracket. The lens assembly is factory focused, so refocusing in the field is not required. The lens unit is removed from the front of the signal case by the removal of two screws. To replace the lens unit, perform the following steps: a. Disconnect the power to the signal. b. Disconnect the two leads to the lamp bracket. c. Working from the front of the signal, remove the two screws holding the lens housing to the case. Save the screws. d. The lens unit will now be free of the case and can be removed. e. The replacement lens unit is already focused. Install it following the removal steps above in the reverse order. If deflecting or spreadlight lenses are used, ensure that the lenses are aimed properly (refer to Section 2.3). 3.4 Lens Replacement Outer lens Inner lens a. Remove the lens hood, if attached to the lens housing. b. Remove the screws attaching the lens ring to the lens housing. Save the screws. c. Remove lens, clean the inside surface of the new lens, and install. d. Reinstall the lens ring and hood, if applicable. e. Clean outer surface of the new lens. Note: The inner lens can be replaced without removing the lens housing by working inside the signal case (see Figure 3- on next page). a. Disconnect power and remove the lamp. b. Loosen the fastening clips and remove the inner lens. c. Clean the inner surface of the new lens and install. d. Tighten the fastening clips. e. Clean the outer surface of the lens. 3-
MAINTENANCE 3.5 Lamp Bracket Replacement The lamp bracket is factory preset and should not be repaired in the field. Return defective lamp brackets, with lens housing, to US&S for repair or, if desired, replace in the Railroad Maintenance Shop. Replacement of the lamp bracket requires focusing of the signal. Only those railroad shops equipped for focusing signals should perform this replacement. 3.6 Lamp Replacement When replacing a burned out lamp, ensure the pins on the lamp base are turned to the end of the slot in the receptacle and forced into their seats by the contact spring. This will assure proper positioning of the filament. Figure 3-. Transit Style Signal Case With Lens Unit 3.7 Case Lubrication Newer units are provided with a sealed hinge, therefore no hinge lubrication is required. For units without this feature, the hinge, as well as the padlock handle, should periodically be lightly oiled with a light machine oil where moving parts touch. Wipe off excess oil. 3-2
APPENDIX A PARTS LISTS AND DIAGRAMS A. Signal, One Color Light (N45623520) Parts List (see Figure A-) Drawing Item Number Description Qty Per Assembly Part Number 2 3 6 7 8 9 0 20 23 24 30 Case & Door Lens Unit (red) Transformer WZ Bracket Screw, /4-20 x -/4 Hex Washer-SST Lock No /4 Screw, 0-32 x 3/4 Pan HD Screw, 0-32 x 5/8 Pan HD Nut, 0-32, SS Stop Screw, 4-24 x -5/8 Fil Screw, SST 0-32 x 3/8 Pan Washer, SST Lock 3/8 Threadlocker-290 2 2 4 4 8 2 4 4 N456330 N27954300 N4503930 M4587540 J500079020 J47520 J50729602 J50729600 J480256 J05396 J507296006 J475203 J046080004 A-
APPENDIX A PARTS LISTS AND DIAGRAMS Figure A-. Signal, One Color Light (N45623520/red aspect)) A-2
APPENDIX A PARTS LISTS AND DIAGRAMS A.2 Lens Unit (N27954300) Drawing Item Number Description Qty Per Assembly Part Number 5 0 5 20 25 30 35 40 45 50 60 75 80 Lens Housing Lens, Red 5-/2 Dia. Lens, Clear Lexan 6-3/8 Dia. Clip, Inner Lens (not shown) Screw, 0-32 x /4 Fil Hd (for clip)(not shown) Washer, SST 0-32 x 3/8 Pan (for clip)(not shown) Screw, SST 0-32 x 3/8 Pan Lens Ring Lamp Receptacle Comp Screw, #4-24 Hex SS Sealer, Duct M-7389 (not shown) Separator, /2 Aluminum Rd Nut, #24 x 4 Copper Lock 4 4 4 7 2-2 2 M436242 J0533 J05325 M07673500 J525282004 J4752009 J507296006 M435827 PN277867 M453582828 A04498 M27786 M28339 Figure A-2. Lens Unit (Two Lamp) A-3