AnsaldoSTS 95 Instruction Manual

1000 Technology Drive, Pittsburgh, PA 15219
645 Russell Street, Batesburg, SC 29006 SM 6495
Copyright © 2008 December 2008
Union Switch & Signal Inc. Rev. 7
MODEL 95
Highway Crossing Gate Mechanism
12-Volt Systems
24-Volt Systems
Highway Crossings
Pedestrian Crossings
Sidewalk Crossings
♦Installation
♦Maintenance

Notices
SM 6495, Rev. 7, December 2008 i
Proprietary Notice
This document and its contents are the property of Union Switch & Signal Inc. (hereinafter US&S).
This document has been furnished to you on the following conditions: no right or license under any
patents or any other proprietary right in respect of this document or its content is given or waived in
supplying this document. This document or its content are not to be used or treated in any manner
inconsistent with the rights of US&S, or to its detriment, and are not to be copied, reproduced,
disclosed to others, or disposed of except with the prior written consent of US&S.
IMPORTANT NOTICE
This document and its contents are the property of Union Switch & Signal Inc. (hereinafter US&S).
This document has been furnished to you on the following conditions: no right or license under any
patents or any other proprietary right in respect of this document or its content is given or waived in
supplying this document. This document or its content is not to be used or treated in any manner
inconsistent with the rights of US&S, or to its detriment, and are not to be copied, reproduced,
disclosed to others, or transferred without the prior written consent of US&S.

Revision History
ii SM 6495, Rev. 7, December 2008
Revision History
Rev. Date Nature of Revision
Original September 1996 Original Issue
1 March 1999
2 March 2003 Added new cam clamp in the parts list and updated the parts lists and
figures in general. Added Pedestrian Gate Arm Shield information.
Incorporated terminal block changes. Modified the Test Check List (Table
2-4). Miscellaneous format and editorial changes.
3 September 2003 Incorporated ECO EM-2035. Incorporated information on the redesigned
Power Down Module into the manual and added a new section on its
installation.
Incorporated ECO EM-2006. Added information on the torque readings for
the counterweight installation to include readings with the new torque
wrench being supplied as part of the Torque Wrench Kit (PN 467000-03).
Miscellaneous format and editorial changes.
4 March 2005 Incorporated ECO EM-2177 – Corrected part numbers. Corrected the
motor part number in the parts list. Removed the lists of X-bills from
manual and put the individual parts in the parts lists.
Incorporated ECO EM-2178 – Revised Figures A-4, A-5, A-6, and A-7 to
include the new snub diode. Added specific part numbers to the parts lists.
Items 300, 305, 310, 315 and 320 were added to the parts list for
N46782101 and N46782001.
Incorporated ECO EM-2215A – Removed the stiffener from the parts list
and revised Figures A-4, A-5, A-6, and A-7 to reflect the absence of the
stiffener.
In addition, modified the Warning at the beginning of Section 3 to account
for other mechanisms at a crossing.
Included maintenance switch installation in the manual.
Incorporated ECO EM-2221 – Changed part number X46703701 to
X46703702.
Incorporated ECO EM-2232 - Modified wiring diagrams.
Incorporated CRS-01341 – Added Safety Consideration in Section 3.1 to
prevent backfeed of other gate mechanisms at a crossing when performing
maintenance on one gate mechanism.
Miscellaneous format and editorial changes.
5 July 2005 Incorporated ECO EM-2283 - Added new version of Figure 2- 5.
Corrected identification of Item 320 in Tables 5-2, 5-3, and 5–4.

Revision History
SM 6495, Rev. 7, December 2008 iii
Rev. Date Nature of Revision
6 June 2006 Incorporated ECO EM-1890 – Corrected the description for Part No.
J0523620003 in Tables 5-2, 5-3, and 5-4.
Incorporated ECO EM-2177 – Changed part number J0702051208 for gear
motor to N46703602 in Table 5-2.
Incorporated ECO-EM-2277A – Added new part number PN46716401 and
the description for the relay in Table 5-6.
Incorporated ECO EM-2308 – Changed the part number and name of
N46709102, Toggle Switch Assembly Retrofit to N46790104, Toggle
Switch Assembly Wires in Table 5-10.
Incorporated ECO EM-2352 – Added information on the additional
Pedestrian Mechanism relay. Added new Section 5.8, revised Table 5-9,
and revised Figure 5-14.
Incorporated ECO EM-2356B – Added Warning Label, PN M46717401 to
Table 5-11.
Incorporated ECO EM-2387 – Added parts list for the Snub Components
Upgrade kit to the manual as Table 5-16.
Incorporated ECO EM-2515A – Figure 2-6 was revised to include the latest
revision of Drawing 467173.
Incorporated ECO EM-2564, added new Section 4.3 on “severe weather
shocks” and added part number 46701402 to Tables 5-2, 5-3, and 5-4.
Added new part number N46780202 (24-Volt Vital Mechanism).
Replaced Section 3.2.10 with new procedure requiring disassembly of the
gear motor to eliminate grounds in the motor rather than just blowing the
motor out through the brush access ports.
7 December 2008 Incorporated ECO EM-3028 – Added part number N156683 to Table 5-5,
Item Number 40.
Incorporated ECO EM-2712 – Revised Tables 5-5 and 5-7. Revised
Figures 5-10 and 5-12. Electrical assemblies changed.
Incorporated ECO EM-2709 – Revised Tables 5-6, 5-8, and 5-9. Revised
Figures 5-11, 5-13, and 5-14. Gate mechanism non-vital relay cover
eliminated.
Incorporated ECO EM-2660 – Revised Table 5-17. Conversion bracket
assembly part number changed.
Incorporated ECO EM-2647 – Revised Tables 5-7 and 5-8. Resistor part
number changed.
Incorporated ECO EM-2684 – Revised Table 5-10 and Figure 5-16.

Revision History
iv SM 6495, Rev. 7, December 2008

Table of Contents
SM 6495, Rev. 7, December 2008 v
Table of Contents
1. INTRODUCTION................................................................................................................................1-1
1.1. Description and General Operation..........................................................................................1-1
1.2. Reference Documents..............................................................................................................1-3
1.3. Parts List Ordering References.................................................................................................1-3
1.4. Major Installation Parts .............................................................................................................1-4
2. INSTALLATION.................................................................................................................................2-1
2.1. Introduction ...............................................................................................................................2-1
2.1.1. Required Tools..............................................................................................................2-1
2.1.2. Foundations ..................................................................................................................2-1
2.2. Mast Mounting ..........................................................................................................................2-1
2.2.1. Mast Mounting for Sidewalk Gate Mechanisms............................................................2-2
2.2.2. Pedestrian Gate Shield Installation...............................................................................2-4
2.3. Power and Control Wiring.........................................................................................................2-5
2.3.1. Power Supply Filtering and Regulation Test for Non-Battery Operation for
12 and 24 VDC Systems...............................................................................................2-6
2.3.2. Wiring Diagram for 12-Volt Systems.............................................................................2-7
2.3.3. Wiring Diagram for 24-Volt Systems.............................................................................2-7
2.3.4. Wiring Diagram for 3-Wire Control 12-Volt Systems ....................................................2-7
2.3.5. Wiring Diagram for Pedestrian Mechanism 12-Volt Systems.......................................2-8
2.4. Spring Buffer Adjustment........................................................................................................2-15
2.4.1. Horizontal (Down) Buffer Adjustment ........................................................................ 2-15
2.4.2. Vertical (Up) Buffer Adjustment ................................................................................. 2-15
2.5. Torque Testing and Adjustments............................................................................................2-15
2.5.1. Torque Testing (Not required for Sidewalk Gate Mechanisms)................................. 2-15
2.5.2. Horizontal Adjustment................................................................................................ 2-16
2.5.3. Vertical Adjustment.................................................................................................... 2-17
2.6. Cam Adjustment .....................................................................................................................2-17
2.7. Gate Arm Ascent and Descent Time Test (12-Volt Systems) ................................................2-18
2.7.1. Gate Arm Ascent and Descent Time Test (24-Volt Systems) ................................... 2-19
2.7.2. Circuit Breaker ........................................................................................................... 2-19
2.8. Test Checklist..........................................................................................................................2-20
3. GENERAL MAINTENANCE AND TROUBLESHOOTING ...............................................................3-1
3.1. Safety Considerations at Multiple Gate Locations....................................................................3-1
3.2. General Maintenance................................................................................................................3-2
3.2.1. Periodic Maintenance ...................................................................................................3-2
3.2.2. Control Relays...............................................................................................................3-2
3.2.3. Contact Adjustments.....................................................................................................3-2
3.2.4. Electrical Assembly.......................................................................................................3-3
3.2.5. Hold Clear Device (Brake) Removal/Replacement and Testing Procedure.................3-4
3.2.6. Gearmotor.....................................................................................................................3-7
3.2.7. Idler Gear Assembly .....................................................................................................3-8
3.2.8. Main Shaft and Segment Gear .....................................................................................3-8

Table of Contents
vi SM 6495, Rev. 7, December 2008
3.2.9. Power Down of the Gate Arm.......................................................................................3-9
3.2.10.Eliminating Brush Dust Related System Grounds in the Gearmotor......................... 3-11
3.2.11.Installing the Power Down Module Upgrade Kit ........................................................ 3-12
3.3. Troubleshooting (General)......................................................................................................3-15
3.3.1. Testing and Troubleshooting the Power Down Module for 12-Volt Systems............ 3-15
3.3.2. Testing and Troubleshooting the Power Down Module for 24-Volt Systems............ 3-16
3.3.3. Verification of Maintenance Switch Operation........................................................... 3-16
4. OPTIONAL EQUIPMENT..................................................................................................................4-1
4.1. Heater (Defroster).....................................................................................................................4-1
4.1.1. Installation Instructions for Model 95 Gate Mechanism Heater Kit...............................4-1
4.2. Maintenance Switch..................................................................................................................4-1
4.3. Severe Weather Shock Option .................................................................................................4-1
5. PARTS LISTS AND EQUIPMENT DIAGRAMS................................................................................5-1
5.1. Model 95 Gate Mechanism – Mechanical Assembly Parts List
(12- and 24-Volt Systems)........................................................................................................5-2
5.2. Model 95 Pedestrian Gate Mechanism - Mechanical Assembly Parts List..............................5-6
5.3. Model 95 Sidewalk Gate Mechanism - Mechanical Assembly Parts List...............................5-12
5.4. Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems) (N46782101).............................................................................................5-17
5.5. Non-Vital Relay Electrical Assembly for 12-Volt Systems (N46782001)................................5-20
5.6. PN-150 Electrical Assembly for 24-Volt Systems (N46782102).............................................5-23
5.7. Non-Vital Relay Electrical Assembly for 24-volt Systems (N46782002).................................5-26
5.8. Non-Vital Pedestrian Mechanism Relays Electrical Assembly for
12-Volt Systems (N46782201, N46782202) ..........................................................................5-29
5.9. Model 95 Maintenance Switch................................................................................................5-31
5.10. Tool Kit (N46707001).............................................................................................................5-33
5.11. Recommended Model 95 Non-Vital Gate Mech Spare Parts Kit (X46700016)......................5-34
5.11.1.Recommended Spare Parts Not Contained in the Spare Parts Kit........................... 5-34
5.12. Model 95 Gate Mech Torque Wrench Kit (X46700003) .........................................................5-34
5.13. Power Down Module Upgrade Kit (X46700031).....................................................................5-35
5.14. Snub Component Upgrade Kit................................................................................................5-35
5.15. Accessories for the Model 95 Gate Mechanism.....................................................................5-35
5.16. Gate Arm Light Fuse Retrofit Kit.............................................................................................5-37
6. GATE ARM CLEARING GRAPHS....................................................................................................6-1
7. TECHNICAL SUPPORT....................................................................................................................7-1

Table of Contents
SM 6495, Rev. 7, December 2008 vii
List of Figures
Figure 1-1 - Model 95 Gate Mechanism Basic Configurations ................................................................1-2
Figure 1-2 - Original and Redesigned Power Down Modules..................................................................1-4
Figure 1-3 - Model 95 Gate Mechanism Major Installation Parts.............................................................1-5
Figure 2-1 - Completed Pedestrian Crossing Gate Arm Shield Installation.............................................2-5
Figure 2-2 - Wiring Diagram for 12-Volt Systems – with Maintenance Switch ........................................2-9
Figure 2-3 - Wiring Diagram for 12-Volt Systems – without Maintenance Switch .................................2-10
Figure 2-4 - Wiring Diagram for 24-Volt Systems ..................................................................................2-11
Figure 2-5 - Wiring Diagram for 3-Wire Control 12-Volt Systems..........................................................2-12
Figure 2-6 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems with
Maintenance Switch ..........................................................................................................2-13
Figure 2-7 - Wiring Diagram for Pedestrian Mechanism 12-Volt Systems without
Maintenance Switch ..........................................................................................................2-14
Figure 2-8 - Torque Increase/Decrease Diagram ..................................................................................2-16
Figure 2-9 - Number 1 Contact...............................................................................................................2-18
Figure 3-1 - Hold Clear Device.................................................................................................................3-5
Figure 3-2 - Installation Close-up...........................................................................................................3-10
Figure 3-3 - Location of the Power Down Module (Units Manufactured
Before September 1, 2003)...............................................................................................3-13
Figure 3-4 - Proper Hardware Configuration on Terminal Posts 1C, 2C, and 3C..................................3-14
Figure 3-5 - Location of Redesigned Power Down Module on Terminal Posts 1C, 2C, and 3C..........3-14
Figure 5-1 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 1 of 2)....................................5-4
Figure 5-2 - Model 95 Gate Mechanism – Mechanical Assembly (Sheet 2 of 2)....................................5-5
Figure 5-3 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 1 of 4) .................5-8
Figure 5-4 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 2 of 4) .................5-9
Figure 5-5 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 3 of 4)................5-10
Figure 5-6 - Model 95 Pedestrian Gate Mechanism – Mechanical Assembly (Sheet 4 of 4) ...............5-11
Figure 5-7 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 1 of 3)
(RH Shown – LH Available)...............................................................................................5-14
Figure 5-8 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 2 of 3)
(RH Shown – LH Available)...............................................................................................5-15
Figure 5-9 - Model 95 Sidewalk Gate Mechanism – Mechanical Assembly (Sheet 3 of 3)
(RH Shown – LH Available)...............................................................................................5-16
Figure 5-10 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(12-Volt Systems)..............................................................................................................5-19

Table of Contents
viii SM 6495, Rev. 7, December 2008
Figure 5-11 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(12-Volt Systems)..............................................................................................................5-22
Figure 5-12 - Model 95 Gate Mechanism Electrical Assembly with PN-150 Relay
(24-Volt Systems)..............................................................................................................5-25
Figure 5-13 - Model 95 Gate Mechanism Electrical Assembly with Non-Vital Relay
(24-Volt Systems)..............................................................................................................5-28
Figure 5-14 - Non-Vital Pedestrian Mechanism Relay, Electrical Assembly ..........................................5-30
Figure 5-15 - Maintenance Switch Retrofit Assembly (N46709202)......................................................5-31
Figure 5-16 - Maintenance Switch Installation.......................................................................................5-32
Figure 5-17 - Tool Kit (N46707001) .......................................................................................................5-33
Figure 5-18 - Gate Arm Light Fuse Retrofit Kit.......................................................................................5-38
Figure 6-1 - Ten-Second Gate Arm Clearing Graph................................................................................6-1
Figure 6-2 - Fifteen-Second Gate Arm Clearing Graph...........................................................................6-2
Figure 6-3 - Twenty-Second Gate Arm Clearing Graph...........................................................................6-3