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Transportation Systems

Operating Manual

SIMAX S700 K Electric Point Machine

Electric Point Machine S700 K SIMAX S700 K OKZ: ! DCC: EDC013


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Transportation Systems Change List

Revision level 01 Date Signature Name Org. unit Date Signature Name Org. unit 03 Date Signature Name Org. unit 04 Date Signature Name Org. unit 05 Date Signature Name Org. unit

Prepared
01-04-1997 Brock VT 1 P 64 29-07-1997 sgd. Brock Brock VT 1 P 64 30-01-2001 sgd. Plattfaut-Yousefi Plattfaut-Yousefi TS AR CO DOC 23-03-2001 sgd. Christ Christ TS AR CO DOC 30-03-2001 sgd. Christ Christ TS AR CO DOC

Proof-read
01-04-1997 Lautenbach VT 1 P 64 29-07-1997 sgd. Lautenbach Lautenbach VT 1 P 64 30-01-2001 sgd. Staab Staab TS AR CO DOC 23-03-2001 sgd. Staab Staab TS AR CO DOC 30-03-2001 sgd. Staab Staab TS AR CO DOC

Checked

(Translated)

Released

02

30-07-1997 sgd. Bumann Bumann VT 1 P 32 06-03-2001 sgd. Bumann Bumann TS AR CO PM 26-03-2001 sgd. Bumann Bumann TS AR CO PM 30-03-2001 sgd. Bumann Bumann TS AR CO PM 06-03-2001 sgd. Argiel Argiel TS AR CO DOC 26-03-2001 sgd. Argiel Argiel TS AR CO DOC 30-03-2001 sgd. Argiel Argiel TS AR CO DOC

30-07-1997 sgd. Bumann Bumann VT 1 P 32 06-03-2001 sgd. Bumann Bumann TS AR CO PM 26-03-2001 sgd. Bumann Bumann TS AR CO PM 30-03-2001 sgd. Bumann Bumann TS AR CO PM

Electric Point Machine S700 K SIMAX S700 K OKZ: ! DCC: EDC013


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Transportation Systems Table of Contents


Page
Change List .............................................................................................................. 2 Table of Contents......................................................................................................... 3 List of Figures .............................................................................................................. 5 List of Tables .............................................................................................................. 6 List of Abbreviations ................................................................................................... 7 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4 4.5 4.6 5 5.1 5.2 5.3 6 7 8 Purpose of this Manual................................................................................................ 8 Address of the Manufacturer and Customer Service ............................................... 9 Safety Regulations ..................................................................................................... 10 Symbols and Pictograms Used .................................................................................... 10 Basic Safety Regulations ............................................................................................. 10 Qualified Staff............................................................................................................... 11 Safety-minded Work..................................................................................................... 11 Proper Use ................................................................................................................... 11 Handling of Detergents, Lubricants and Paints............................................................ 12 Earthing of the Point Machine Housing........................................................................ 12 Transport of the SIMAX S700 K Electric Point Machine .............................................. 12 Constructional Details and Principle of Operation................................................. 13 Functions of the SIMAX S700 K Electric Point Machine.............................................. 13 Constructional Details .................................................................................................. 13 Housing ........................................................................................................................ 13 Cable Entry................................................................................................................... 13 Earthing ........................................................................................................................ 14 Internal Wiring .............................................................................................................. 14 Technical Description................................................................................................... 14 Motor ............................................................................................................................ 16 Transmission Clutch..................................................................................................... 16 Gearing......................................................................................................................... 16 Retention Clutch with Throw Bar.................................................................................. 17 Point Detector............................................................................................................... 17 Contact Assembly ........................................................................................................ 17 Efficiency ...................................................................................................................... 18 Throwing Process ........................................................................................................ 18 Trailing Process............................................................................................................ 18 Point Throwing with a Crank Handle............................................................................ 19 Technical Data ............................................................................................................ 21 Point Machine Versions ............................................................................................... 22 Dimension Drawings .................................................................................................... 22 Circuit Diagrams........................................................................................................... 23 Trackside Mounting ................................................................................................... 24 Commissioning .......................................................................................................... 27 Maintenance and Repair............................................................................................ 28 TS AR CO DOC Siemens code no.: 01-04-1997 A25000-X22-Q25-5-7620 30-03-2001 Doc. no.: M0101637663
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8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.4.1 8.1.4.2 8.1.4.3 8.1.4.4 8.1.4.5 8.1.4.6 8.1.5 8.1.5.1 8.1.5.2 8.1.5.3 8.1.5.4 8.1.5.5 8.1.5.6 8.1.5.7 8.2 8.2.1 8.2.2 8.2.3 8.2.3.1 8.2.3.2 8.2.3.3 8.2.3.4 8.2.3.5 8.2.3.6 8.2.3.7 8.2.3.8 8.2.3.9 8.2.3.10 8.2.3.11 8.2.3.12 8.3 8.3.1 8.3.2 8.4 8.4.1 8.4.2 8.4.2.1 8.4.2.2 8.4.2.3 8.4.2.4 8.4.2.5 8.4.2.6 8.4.2.7 8.4.3 Inspection and Maintenance ........................................................................................ 28 Technical Information relating to Inspection and Maintenance Work .......................... 28 Inspection and Maintenance Intervals ......................................................................... 29 Components of the SIMAX S700 K Electric Point Machine......................................... 30 Inspection Work............................................................................................................ 30 Open Machine Housing and Check Interior ................................................................. 30 Inspect Components .................................................................................................... 31 Check Condition of Cable Harness .............................................................................. 31 Check Connection between Machine Housing and Rail (Earthing) ............................. 31 Check Crank Handle Latch and Voltage Cut-off Switch .............................................. 32 Check Machine is Secure and Check Mounting Conditions ........................................ 33 Maintenance Work ....................................................................................................... 33 Grease Throw Bar ........................................................................................................ 33 Grease Ball Spindle ..................................................................................................... 33 Grease Gear Wheels ................................................................................................... 33 Grease and Oil Point Detector ..................................................................................... 34 Oil Keep-and-Detect Slides.......................................................................................... 34 Oil Shifting Plate........................................................................................................... 35 Check Easy Movement of Cover Lock......................................................................... 35 Repair Work ................................................................................................................. 36 Technical Information relating to Repair Work............................................................. 37 Tools and Materials ...................................................................................................... 37 Removal and Fitting of Components............................................................................ 37 Remove Three-phase Motor ........................................................................................ 37 Remove and Fit Point Detector .................................................................................... 38 Exchange Guide Flanges............................................................................................. 41 Remove and Fit Ball Spindle Drive with Transmission Clutch ..................................... 42 Remove Bearing of the Ball Spindle ............................................................................ 44 Remove and Fit Keep-and-Detect Slides..................................................................... 45 Remove and Fit Throw Bar and Retention Clutch ....................................................... 46 Remove Cover Lock..................................................................................................... 48 Exchange Contact Assembly ....................................................................................... 49 Remove Voltage Cut-off Switch ................................................................................... 50 Exchange Contact Assembly with Switches V25124-Z1-A9 for Contact Assembly with Switches V25124-Z1-A19 ............................................................................................ 50 Remove and Fit Limit Switches.................................................................................... 56 Final Work .................................................................................................................... 57 Run In the Point Machine............................................................................................. 57 Add Inspection Stamp .................................................................................................. 57 Testing after Maintenance and Repair Work ............................................................... 57 High-Voltage Test ........................................................................................................ 57 Function Check-out ...................................................................................................... 57 Test Voltage ................................................................................................................. 57 Retention Force............................................................................................................ 58 Trailing Resistance....................................................................................................... 58 Throwing Force ............................................................................................................ 58 Blocking........................................................................................................................ 58 Throwing Time and Running Current ........................................................................... 58 Sealing ......................................................................................................................... 60 Test Stamps and Test Records.................................................................................... 61

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Transportation Systems List of Figures


Page
Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Fig. 32 Fig. 33 Fig. 34 Function chart of the SIMAX S700K electric point machine ........................................ 15 Throwing points with a crank handle............................................................................ 20 Dimension drawings for side view (above) and top view (below) ................................ 22 Examples of typical point machine circuits .................................................................. 23 Trackside mounting on base plates (side view) ........................................................... 24 Trackside mounting on base plates (top view)............................................................. 25 Components of the SIMAX S700 K electric point machine.......................................... 30 Crank handle latch ....................................................................................................... 32 Hole for oiling point detector ........................................................................................ 34 Hole for oiling keep-and-detect slides .......................................................................... 35 Surfaces for oiling the shifting plate ............................................................................. 36 Assembly drawing of the motor.................................................................................... 38 Assembly drawing of the point detector ....................................................................... 39 Assembly drawing of the pointer .................................................................................. 40 Assembly drawing of the guide flanges ....................................................................... 41 Sealing the guide flange............................................................................................... 42 Assembly drawing of the ball spindle drive .................................................................. 43 Assembly drawing of the ball bearing .......................................................................... 44 Assembly drawing of the keep-and-detect slide .......................................................... 45 Assembly drawing of the throw bar and retention clutch ............................................. 47 Assembly drawing of the cover lock............................................................................. 48 Assembly drawing of the contact assembly ................................................................. 49 Installing a new contact assembly................................................................................ 50 Terminal connection diagram....................................................................................... 51 Circuit diagram ............................................................................................................. 51 Position of adhesive label ............................................................................................ 52 Type labels ................................................................................................................... 52 Throw bar in for left-hand version, throw bar out for right-hand version ...................... 53 Throw bar in mid-way position for left-hand and right-hand versions .......................... 54 Throw bar out for left-hand version, throw bar in for right-hand version ...................... 55 Assembly drawing of the limit switch ........................................................................... 56 Position of the pointer at 160 mm detector slide stroke............................................... 61 Position of the pointer at 68 mm to 90 mm and 98 mm to 119 mm detector slide stroke ..................................................................................................................................... 61 Test configuration for function check-out ..................................................................... 62

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Transportation Systems List of Tables


Page
Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Inspection and maintenance jobs and intervals ........................................................... 29 Old/new Siemens code numbers for type labels.......................................................... 52 Throw bar in for left-hand version, throw bar out for right-hand version ...................... 53 Throw bar in mid-way position for left-hand and right-hand versions .......................... 54 Throw bar out for left-hand version, throw bar in for right-hand version ...................... 55 Test values ................................................................................................................... 59 Empty table for recording the values measured during the function check-out........ 60

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Transportation Systems List of Abbreviations


Abbreviation AC DIN IEC PCB PVC VDE VDI Alternating current Deutsches Institut fr Normung (German Institute for Standardisation) International Electrotechnical Commission Polychlorinated biphenyl Polyvinyl chloride Verband Deutscher Elektrotechniker (German Association of Electrical Engineers) Verein Deutscher Ingenieure (German Association of Engineers) Meaning

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Transportation Systems 1 Purpose of this Manual


The contents of this manual cover handling, trackside mounting, commissioning, maintenance, repair and testing of the SIMAX S700 K electric point machine. In addition, this documentation contains information concerning the safety of staff, technical data of the point machine and tools to be used for maintenance and repair as well as information required for its proper use. The information is presented as text and figures. The manual has been compiled to enable qualified staff to perform the necessary maintenance and repair work. Where a risk of injury or damage cannot be totally ruled out, attention is drawn to the dangers by pictograms. An explanation of the pictograms is given in Section 3.1. Suggestions Do you have any useful hints, comments or suggestions concerning this manual? Perhaps you have spotted an error or know how we could optimise a particular procedure? Please contact us direct. We welcome your ideas and suggestions.

(
FAX

Siemens AG Transportation Systems TS AR CO DOC P.O. Box 33 27 D-38023 Brunswick Germany -5 31-2 26-35 33 -5 31-2 26-46 92

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Transportation Systems 2 Address of the Manufacturer and Customer Service


+
Siemens AG Transportation Systems P.O. Box 91 02 20 D-12414 Berlin Germany -30-386-50 -30-386-51531

(
FAX

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Transportation Systems 3 Safety Regulations


This Section tells you what regulations need to be observed for the handling, maintenance and repair of the SIMAX S700 K electric point machine.

3.1

Symbols and Pictograms Used


In order to perform the handling, maintenance and repair of the SIMAX S700 K electric point machine correctly, all the instructions described must be followed. Warnings and notes are highlighted by different pictograms, the words "DANGER", "CAUTION", "NOTE" and indented text.

DANGER This pictogram and the associated text draw attention to dangers which are life-threatening or liable to cause injury.

CAUTION This pictogram and the associated text draw attention to dangers which are liable to cause damage to circuit boards or components.

NOTE This pictogram and the associated text point to technical requirements and additional information to be observed by maintenance staff.

3.2

Basic Safety Regulations


To protect staff and prevent physical damage to the SIMAX S700 K electric point machine, the following regulations must be carefully observed. The personnel must be familiar with the contents of this manual in order to ensure safe and correct handling of the SIMAX S700 K electric point machine.

DANGER Maintenance and repair work is performed during normal operations.

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DANGER If you remove the cover of the SIMAX S700 K electric point machine, please take into account that the parts bearing a lightning symbol are carrying a current. The point machine can start to move and the set of points be thrown.

Before beginning work on the track, the appropriate safety measures must be applied in accordance with the current railway regulations. All work is to be performed using only the tools, specialist equipment, test facilities and materials prescribed.

3.3

Qualified Staff
Maintenance and repair work on the SIMAX S700 K electric point machine is only to be performed by specially trained and tested personnel authorised by the operator of the equipment to carry out the installation, maintenance and repair of type SIMAX S700 K point machines.

3.4

Safety-minded Work
The qualified staff referred to in Section 3.3 are responsible for job safety. The SIMAX S700K electric point machine may only be operated if it is in perfect working order. The work must be carried out in such a way that human safety is not diminished nor the operation of the SIMAX S700 K electric point machine impaired. As a rule, safety equipment must not be removed or put out of operation. Safety-minded work implies that staff are to be informed of incorrect actions and any faults detected are to be reported to the authority or person responsible.

3.5

Proper Use
The SIMAX S700 K electric point machine is used to operate points of every gauge. Points with external lockings and, under certain conditions, points without a locking can be operated.

DANGER No unauthorised modifications to the SIMAX S700 K electric point machine are to be carried out. The numbers of the point machines change when being modified.

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3.6 Handling of Detergents, Lubricants and Paints
The following detergents, lubricants and paints are used for the SIMAX S700 K electric point machine: white spirit Molub-Alloy 243 Arktik grease Molykote paste (type G) Tectyl 506 anticorrosive paint RAL 7031 (dark grey) and RAL 3002 (red) lacquers SAE 10 W/40 oil

CAUTION Prevent your skin from coming into contact with the above-mentioned agents, in particular the grease. They (especially grease) can irritate the skin or cause other allergic reactions. Only apply them using gloves and appropriate tools (e.g. a brush).

3.7

Earthing of the Point Machine Housing


The point machine housing must be connected to earth potential or, on electrified lines, to the railway earthing system. Use galvanised iron wire 10 mm in diameter for this purpose. Connect this wire with the housing using one of the two M16 earthing screws.

3.8

Transport of the SIMAX S700 K Electric Point Machine


The SIMAX S700 K electric point machine is generally transported to the installation site by lorry. On account of its weight (110 kg) it must be handled with care.

DANGER Appropriate lifting equipment must be used for the off-loading of the SIMAX S700 K electric point machine (weight of 110 kg) from the lorry and transport on site.

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Transportation Systems 4 Constructional Details and Principle of Operation


Functions of the SIMAX S700 K Electric Point Machine
The SIMAX S700 K electric point machine is used to operate points with external lockings and, under certain conditions, points without their own locking components. It has the following functions: operate points retain point blades in end positions lock point blades in end positions prove home position of point blades electrically The SIMAX S700 K electric point machine is available as a trailable or a nontrailable version, for right-hand or left-hand mounting and with or without a point detector. In addition, the models differ in the type of motor current, throwing stroke, throwing force and throwing time. A throwing movement already initiated can be reversed at any time and from any position. If the current fails, the point machine can be operated using a crank handle.

4.1

4.2

Constructional Details
All the components are neatly arranged in a machine housing. Parts which need to be checked during interlocking inspections and maintenance work are easily accessible. For environmental reasons, the point machine is free of asbestos, PVC and PCB.

4.2.1

Housing
The housing of the point machine conforms to IP rating IP 54 as per German standard DIN VDE 0470. The inside can be ventilated. Any water which may have collected can be drained off via holes. During storage and transport, these holes are closed by water drainage stoppers; they are removed after the point machine has been mounted on the track. The outlets for the throw bar and detector slides, the lock cover and opening for the crank handle are well sealed. The efficiency of the point machine cannot be impaired by the entry of moisture. The housing cover has a built-in lock.

4.2.2

Cable Entry
Cables entering the machine are insulated from the housing; this is ensured by a cable gland at the side of the point machine. The terminal strip has eight terminals for connection of the cables. Depending on the voltage cut-off switch provided, up to eight cores can be connected.

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4.2.3 Earthing
M16 earthing screws are provided on the two long sides of the machine housing (see also Section 3.7).

4.2.4

Internal Wiring
For the internal wiring flexible wires are used, which are bundled together. Contact areas subject to particular stress are covered with a protective hose. With the exception of two connections, which may have to be interchanged to reverse the motor, the terminals are unambiguously marked. The dielectric strength of all current-carrying parts with respect to earth is 2000 V, 50 Hz (VDE 0831). A diagram of the internal circuitry is affixed to the housing cover of the point machine.

4.3

Technical Description
Fig. 1 is a function chart of the point machine with index numbers which are explained in the text below. The diagram is intended as a guide; mechanical details have therefore been omitted.

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2 3 5 4

8 12 1 6 6.1 9 6.2 7 16.1 16.2 13 11 8.1 9.1 16.3 10

14

14.1 16 15

No Part
1 2 3 4 5 6 6.1 6.2 Motor Motor pinion Intermediate gear wheel Gear wheel Transmission clutch Ball spindle drive Carrier Carrier

No Part
7 8 8.1 9 9.1 10 11 12 Shifting plate Keep-and-detect slides Roller Keep-and-detect slides Roller Compression spring Compression spring Snap switch

No
13 14 14.1 15 16 16.1 16.2 16.3

Part
Snap switch Retention clutch Roller Detector slide Throw bar Notch of throw bar Notch of throw bar Notch of throw bar

Fig. 1

Function chart of the SIMAX S700K electric point machine

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4.3.1 Motor
The encased built-in motor (1), an asynchronous short-circuit motor for threephase AC, was specially adapted to the construction of the point machine. The motor is designed for short-time duty. It has a high starting torque and the starting current is damped to permit operation with different line resistances. The rotor shaft, resting on ball bearings, supports the motor pinion (2). A crank handle gear wheel is provided for the insertion of the crank handle. An intermediate gear wheel (3) mounted on a pin on the motor engages with the pinion. This intermediate gear wheel bridges the axial clearance to the gear wheel of the transmission clutch (5). Also mounted on the pin is a lever which operates a voltage cut-off switch for crank handle operation. A suitable tolerance combination between the motor attachment and gear wheels ensures a perfect engagement with the transmission clutch gear wheel (4) even if the motor is exchanged. The motor complies with German VDE specifications.

4.3.2

Transmission Clutch
A multiple-disc clutch (5) limits the throwing force. The torque is transmitted to a sintered disc by two steel discs. The throwing force remains constant throughout the entire working life of the clutch. This is due to the long service life of the clutch, the flat characteristics of the spiral springs by means of which the pressure force is produced, and the relatively low surface pressure. The transmission clutch is mounted as a complete unit. The housing parts are made of light metal alloy. The clutch hub attached to the output end remains stationary when the clutch slips. The slipping clutch part at the motor end, incorporating the clutch housing with the gear wheel, forms the actual flywheel mass and rests on the hub. The adjusting screw allows an adjustment of the throwing force. The ex works setting is 5500 N 500 N. The clutch setting is secured by means of a form-fit locking plate and sealed. A throwing movement already initiated can be reversed at any time and from any position.

4.3.3

Gearing
The torque of the motor (1) has to be transformed into the necessary throwing force. The rotary movement is converted into the straight movement of the throw bar (16) by a ball spindle drive (6) via reduction gearing (2, 3, 4) and the transmission clutch (5). The ball spindle drive permits a high transmission ratio and produces linear motion. The spindle and spindle nut intermesh via rolling balls. The movement is transmitted from the spindle to the spindle nut by rolling friction. The longitudinal motion required results from the axial travel of the spindle nut. The spindle nut passes on the longitudinal motion to the secondary components via carriers (6.1, 6.2).

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4.3.4 Retention Clutch with Throw Bar
The retention clutch (14) is a notched clutch. It is attached directly to the throw bar (16), which is thus completely enclosed by the clutch housing. The retention clutch comprises a pretensioned spiral spring, which presses a guided roller (14.1) into the hardened notch (16.1) of the throw bar. The pretensioning of the spring determines the retention force. It is adjusted by means of a nut, which is then form-locked and sealed. Trailable points are held in the two home positions with a retention force of 7000 N 500 N . When points are trailed, the notch of the throw bar lifts out the roller, thereby compressing the retention spring. The trailing resistance is 9000 N + 500 N. It is created by the spring pressure and the friction between the throw bar and the guides in the clutch housing, together with the guide flanges on the machine housing. In non-trailable point machines the latching bolt of the retention clutch is blocked. On the clutch housing there is also a shifting plate (7) supported by a guide. The plate engages a keep-and-detect slide (8 or 9) at the beginning of the throwing process and unblocks the clutch housing. The throw bar has a throwing stroke of 220 mm. For a throwing force of 4500 N and core resistance of 54 , the throwing time is approx. 6 seconds.

4.3.5

Point Detector
The point machine is equipped with a point detector consisting of a pair of detector slides and a guide sleeve. The point detector proves the home (end) position of the point blades. A home position is only indicated if the prescribed distance between the point blades and the stock rail is maintained. If the connection between the points and point machine is interrupted, e.g. due to a fractured throw rod, the point detector retains the points in the home position. The point fault becomes apparent the next time the points are operated and no "end position reached" indication is issued. A fractured detector rod can be detected in the same way. The detector slides (15) have notches enabling them to lock the relevant home position. The joints on the detector slides are insulated.

4.3.6

Contact Assembly
Snap switches (12 and 13) are used as the switching elements. For the four-core three-phase point circuit changeover contacts are required. These are operated by the quick-switch mechanism of the snap switch, making a mid-way position of the contacts impossible. The contacts are arranged in such a way that a home position of the points cannot be indicated until the throw bar and detector slides have reached their end positions. The end position of the throw bar must correspond to the position of the points.

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4.3.7 Efficiency
The point machine has a good overall efficiency. Under normal conditions, therefore, feeder cables having a core diameter of less than 1.8 mm can be used. Alternatively, a greater control range is possible. The following are responsible for the high efficiency: four-pole three-phase motor antifriction bearings ball spindle drive

4.4

Throwing Process
The motor (1) starts up. The torque is transmitted by the pinion (2) via the intermediate gear wheel (3) to the gear wheel (4), and via the transmission clutch (5) to the ball spindle drive with the spindle nut (6). The clutch limits the torque, which is converted into a longitudinal force by the axial travel of the spindle nut. Carriers (6.1 and 6.2) move the shifting plate (7) in the direction of thrust. As the sloping edge of the plate moves against the roller (8.1) of the keep-and-detect slide (8), it pushes the slide back against the force of the compression spring (10), causing the snap switch (12) to operate. The detection contact is broken and the throwing current contact made. The retention clutch (14) and the detector slides (15) are then released. In order to ensure correct release of the retention clutch by the keep-and-detect slide, the restoring force of the point blade must not exceed 1400 N. The actual throwing process begins as soon as the machine is no longer locked. Up to this point, the spindle nut has only carried the shifting plate; it now also transports the retention clutch (14), a notched clutch linked to the throw bar (16). The retention clutch transmits the movement of the spindle nut to the throw bar. The retention force (setting of the retention clutch) must always exceed the throwing force in order to prevent a disengagement in the event of a large throwing resistance. At the end of the throwing movement, a compression spring (11) is released, pushing forward the keep-and-detect slide (9) assigned to this end position. The keep-and-detect slide engages with the end position notch (16.2) of the throw bar and locks the retention clutch. For point machines with point detector, the keep-and-detect slide (9) must also engage with the notches of the detector slides (15). The keep-and-detect slide can, therefore, only reach the locking end position if the detector slides have also reached the correct end position. Only under these conditions is it possible for the keep-and-detect slide to operate the snap switch (13), thereby breaking the throwing current contact and making the detection contact. The detector slides (15) are locked in the end position by the keep-and-detect slide (9).

4.5

Trailing Process
A trailable and a non-trailable version of the point machine are available. The trailing resistance is 9000 N + 500 N.

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The retention force of the non-trailable machine is greater than 90 kN. In the home position shown (Figure 1) the keep-and-detect slide (8) retains the throw bar (16) via the retention clutch (14). The throw bar can only be moved if the trailing resistance is overcome. The sloping edge of the notch (16.1) in the throw bar lifts the roller (14.1) of the retention clutch against the force of the retention spring. A second notch (16.3) of the throw bar for the relevant end position shifts the engaged keep-and-detect slide (8). The keep-and-detect slide operates the snap switch (12) and breaks the detection contact. At the same time the locking of the detector slides (15) by the keep-and-detect slide (8) is cancelled. The retention clutch (14) remains locked by the keep-anddetect slide (8). As the trailing process progresses, the throw bar (16) is shifted with respect to the retention clutch (14) after the trailing resistance has been overcome. The point machine is indicated as being trailed as soon as the throw bar is moved, even if the locking of the machine is still effective. After trailing, the point machine must be made operational again. This is done by a point reversal, which allows the retention clutch to catch up with the throw bar until it engages.

4.6

Point Throwing with a Crank Handle


The SIMAX S700 K electric point machine can be reversed locally using a crank handle. The crank handle is inserted on the left or the right of the machine housing, depending on the version, ensuring, thereby, that on double-track lines you must not turn your back to either of tracks in the process. The position of the crank handle opening is such that the cranking is not hindered by ballast or the like. A crank handle latch prevents the crank handle from engaging with the crank handle gear wheel as long as the throwing current is on. A key is used to operate the voltage cut-off switch and release the crank handle gear wheel. The crank handle is inserted through a covered opening in the housing and engaged with the crank handle gear wheel.

DANGER Before you start working on the track, inform the traffic controller responsible in order that he blocks the points. Continually observe the traffic on the adjacent track during the work.

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4500

2000

2300

430

900 dimensions in mm

1 2
Fig. 2

clearance gauge adjacent track

3 4

point machine blocked track

Throwing points with a crank handle

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Type of current Rated voltage Rated current Maximum starting current Frequency Power output (motor) Insulation class (motor) Throwing stroke Point opening Throwing force Restoring force of point blade (open blade for toggle-type point lock) Retention force Trailing resistance

Technical Data
three-phase AC as per DIN IEC 38 380 V AC 2A 8A 50 Hz 2 % 400 W B as per VDE 0530 220 mm 160 mm 5500 N 500 N 1400 N 7000 N 500 N 90 kN for non-trailable point machines 9000 N + 500 N

For a throwing resistance of 4500 N the following data applies: Line resistance Throwing time Control range RL / core 54 approx. 6 s max. 1900 m for 0.9 mm core diameter max. 4640 m for 1.4 mm core diameter max. 7680 m for 1.8 mm core diameter IP 54 as per DIN VDE 0470 1 as per VDE 0100 2000 V, 50 Hz as per VDE 0831 434 mm 534 mm 290 mm 110 kg 25 C to +70 C 1 106 throwing operations TS AR CO DOC Siemens code no.: 01-04-1997 A25000-X22-Q25-5-7620 30-03-2001 Doc. no.: M0101637663
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IP rating Protection class Test voltage Width Length Height Weight Temperature range Service life Electric Point Machine S700 K SIMAX S700 K OKZ: ! DCC: EDC013
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5.1

Point Machine Versions


There are more than 100 SIMAX S700 K point machine versions. It is available as a trailable or a non-trailable version, for right-hand or left-hand mounting and with or without a point detector. In addition, the models differ in the type of motor current, throwing stroke, throwing force, throwing time and pitch of the ball spindle drive. The SIMAX S700 K electric point machine can be easily converted from right-hand to left-hand mounting or vice versa.

5.2

Dimension Drawings
880 534

108 29

68,5

50

22

16 h11 21

75

290 140 430 434 306

25 F8

265

Fig. 3

Dimension drawings for side view (above) and top view (below)

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5.3 Circuit Diagrams
P oint machine P oint machine

1 CS CS

4 CS

3 CS CS

1 CS

3 CS

4 CS

W Z

3a 4a V Y 3 4 1a 2a 2 1 X U

3a 3 1a 1 1 0 2

4a 4 2a 2

4-core three-phase AC circuit

4-core D C and single-phase AC circuit

P oint machine

5 CS CS

6 CS

3 CS

2 CS

4 CS

3 3a 5 5a 6 6a 1 1a W Z V Y

4 4a

C S = voltage cut-off switch

2 2a U X

6-core three-phase AC circuit

Fig. 4

Examples of typical point machine circuits

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For the mounting of the base plates and point machine it is convenient to prepare a 30 cm to 40 cm thick ballast layer in order that rain and melt snow can drain off and seep away. Mount the point machine so that the base plates are horizontal and it cannot be immersed in water or affected by water jets. The base plates must not rest on the ballast. They must be free to move when the points are traversed.
P oint machine

Minimum clearance of 3 cm Soil or ballast Base plate

Fig. 5

Trackside mounting on base plates (side view)

Stamp the ballast and level the rest of the base plates flat. Small concrete plates can also be used as a rest. On the crank handle side the distance to the ballast layer must be such that the cranking is not hindered by ballast. Mounting sequence Attach the base plates to the ribbed sole-plates or sleepers (see 0). Put the point machine on the base plates. Remove the water drainage stoppers. Hook the detector rods in (in point machines with a point detector). Laterally shift the point machine until the detector rods are in alignment with the detector slides and perpendicular to the stock rail. Put the rodding cover on and check that the play between the slide forks and cover is sufficient (take into account lateral play of the rodding cover). Shift the point machine if necessary. Laterally crank the detector rods so that they cannot become stuck with the slide forks. We recommend to temporarily fix the point machine in this position on the base plates using clamps. Connect the upper detector slide with the short and the lower detector slide with the long detector rod (see 0).

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2 4

3 1 2 3 4 5 point machine base plate rodding cover detector rod throw rod

Fig. 6

Trackside mounting on base plates (top view)

Hook the throw rod in and adjust it so that it is in alignment with the throw bar and in parallel with the detector rod, and both bolts can be easily inserted. In the two end positions equalise the clamp overlap of the toggle-type point lock by varying the throw rod length or shifting the point machine. Make sure the point machine is slightly inclined towards the track in order that no water enters the housing via the detector slides or throw bar.

CAUTION The point machine has an IP rating of IP 54 (see Section 5), i.e. it is dust- and splash-proof. Ingress of water projected in jets or when the point machine is immersed may impair or destroy electrical and mechanical components of the point machine. Thus, the point machine must be installed so that it cannot be immersed in water or affected by water jets.

NOTE Re-tighten the fastening bolts of the point machine at least twice in three to six-weeks intervals.

Check that the point opening at the operating rod is in the admissible range (see also data recording sheet of points).

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NOTE If the points fail to reverse (slipping of the transmission clutch), first check the condition of the point blades and toggle-type point lock. If necessary, measure the throwing resistance of the points and throwing force of the point machine using an appropriate meter.

Then run in the point machine and adjust the upper (short) detector rod. If the point opening is in the admissible range of 149 mm to 169 mm, the wide notches take up the correct position automatically.

CAUTION The notches must not be modified.

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After the mounting of the SIMAX S700 K electric point machine, check that it can be reversed perfectly by throwing the points several time. The parts of the point machine must not be greased or oiled when putting it into service.

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8.1
8.1.1

Maintenance and Repair


Inspection and Maintenance
Technical Information relating to Inspection and Maintenance Work
The SIMAX S700 K electric point machine requires little maintenance. All the bearing surfaces remain operational, even if they have not been relubricated for a long period. The SIMAX S700 K electric point machine is insensitive to oils and grease in the machine housing. Any water that enters must be drained off by pulling out the water drainage stopper (see 0). Most of the maintenance jobs required to ensure that the machine is in perfect working order do not take long and can be carried out e.g. during the check of the point locking components by the responsible staff. After each action, check the point machine by throwing the points several times.

CAUTION If you unscrewed or unplugged any cables or internal wiring, make sure you prove the "off" position of the point machine once you have completed the work.

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8.1.2 Inspection and Maintenance Intervals
Inspection jobs in accordance with DS 892 of German Railways (DB AG) Interval: 2 months Open machine housing and check interior Check whether any parts are damaged Check condition of cable harness Check connection between machine housing and rail (earthing) Inspection and maintenance jobs Interval: 1 year Check operation of crank handle latch and voltage cut-off switch Check machine is fixed securely and check mounting conditions Grease throw bar Grease ball spindle Grease gear wheels Grease and oil point detector Oil keep-and-detect slides Oil shifting plate Check easy movement of cover lock
Table 1 Inspection and maintenance jobs and intervals

Techn. information (see Section) 8.1.4.1 8.1.4.2 8.1.4.3 8.1.4.4 Techn. information (see Section) 8.1.4.4 8.1.4.5 8.1.5.1 8.1.5.2 8.1.5.3 8.1.5.4 8.1.5.5 8.1.5.6 8.1.5.7

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8.1.3

Components of the SIMAX S700 K Electric Point Machine

3 45

78 9

1011

12

13

22

21 20

19

18

17 16 15

14

1 detector slides 2 guide sleeve 3 guide flange 4 fastening holes (4 x) 5 voltage cut-off switch 6 disconnection lock 7 keep-and-detect slide 8 earthing screw 9 contact assembly (without cover) 10 adjusting device for detector slides

11 retention clutch 12 cover 13 stop 14 ball spindle 15 ball spindle nut 16 earthing screw 17 water drainage stopper 18 three-phase motor 19 gear wheels 20 transmission clutch 21 crank handle latch 22 throw bar

Fig. 7

Components of the SIMAX S700 K electric point machine

8.1.4
8.1.4.1

Inspection Work
Open Machine Housing and Check Interior The SIMAX S700 K electric point machine is insensitive to oils and grease in the machine housing. Is the interior of the point machine clean and dry? Are the ventilation and drainage holes free? Are the throw bar and detector slides free of rust and lubricated? Are the notches in the detector slides OK in both end positions? Does the housing cover close perfectly (without play) and is the rubber gasket present and intact?

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Are the cover lock and the cover of the lock OK? 8.1.4.2 Inspect Components Examine the components of the SIMAX S700 K electric point machine to see if they are damaged. 8.1.4.3 Check Condition of Cable Harness Make sure the cable harness is held firmly in the cable clamp provided and is not in contact with any movable parts. If the insulation of a cable is damaged, see if any of the copper conductors have been damaged. If a snap switch is damaged and/or there are signs of moisture, exchange the contact assembly. If only the insulation is damaged, wrap the cable with suitable insulating tape. If the copper conductors are damaged, you need to exchange the three-phase motor together with the cable harness (see Section 8.2.3.1). Are the protective covers of the end position contacts and the voltage cut-off switch present and undamaged?

8.1.4.4

Check Connection between Machine Housing and Rail (Earthing) The rules and regulations of the local railway authority must be observed. Check that the connecting wire is securely attached to the earthing screw of the point machine.

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8.1.4.5 Check Crank Handle Latch and Voltage Cut-off Switch
P lay

2 3

1 2
Fig. 8

crank handle gear wheel 3 4 latch lever


Crank handle latch

fork head connecting rod

Are the split pins of the transmission components for the crank handle latch present? When the voltage cut-off switch is on, the latch lever must prevent the insertion of the crank handle. There must be lateral play between the crank handle gear wheel and latch lever. When the voltage cut-off switch is off, it must be possible to insert the crank handle without any difficulty. When the crank handle is inserted, the point machine must not switch on. None of the limit switches must switch on during the test.

CAUTION Do not use force when testing.

Using the nut on the fork head, you can readjust the length of the connecting rod as required. The play should be made as small as possible.

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8.1.4.6 Check Machine is Secure and Check Mounting Conditions Is the throw bar cover free from ballast? Is the point machine fixed securely on the base plates and the ribbed soleplate and are split pins present (except for prevailing torque type hexagon nut)? Is the point identification plate present according to layout diagram and legible? Is the point machine in alignment with the track and the operating rod? Can the cover not be removed after locking?

8.1.5

Maintenance Work
The maintenance work to be done on the SIMAX S700 K electric point machine comprises greasing and oiling of components. Use the following lubricants: Molub-Alloy 243 Arktik grease any commercially available motor oil Other lubricants are not permitted.

CAUTION Prevent your skin from coming into contact with the grease. It can irritate the skin or cause other allergic reactions. Only apply it using gloves and appropriate tools (e.g. a brush).

Grease and oil the following components: 8.1.5.1 Grease Throw Bar Grease the part of the throw bar projecting from the machine housing in the extended position. Grease the part which remains inside the housing in the two end positions of the point machine. 8.1.5.2 Grease Ball Spindle Grease the ball spindle in the two end positions of the point machine, reversing the machine a number of times as you do so. 8.1.5.3 Grease Gear Wheels Grease all four gear wheels with the three-phase motor stopped.

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8.1.5.4 Grease and Oil Point Detector Grease the accessible surfaces of the two detector slides with the slides "in" and "out". Oil the contact surface between the detector slides through the hole in the upper detector slide in accordance with the point machine version: detector slides in for left-hand version detector slides out for right-hand version

Hole for oil

Fig. 9

Hole for oiling point detector

8.1.5.5

Oil Keep-and-Detect Slides Oil the keep-and-detect slides using the hole provided (see 0), reversing the point machine several times as you do so.

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Hole for oil


Fig. 10 Hole for oiling keep-and-detect slides

8.1.5.6

Oil Shifting Plate The sliding surfaces of the shifting plate are accessible laterally from above. First put the point machine in the end position with the greatest distance between the retention clutch and transmission clutch. This is when the retention clutch is on one side and the transmission clutch on the other side of the point machine.

8.1.5.7

Check Easy Movement of Cover Lock You must be able to open and close the housing cover exerting only little pressure. If the cover lock is difficult to operate, first check the bolt hook is functioning properly. If the lock is stiff, lubricate it with some flake graphite. In the winter, if the lock is frozen, you can use a de-icing agent. If these measures prove unsuccessful, exchange the lock as described in Section 8.2.3.8).

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2
Oil here

Oil here

3 1 2 3 retention clutch throw bar shifting plate

Fig. 11

Surfaces for oiling the shifting plate

8.2

Repair Work
An SIMAX S700 K electric point machine must be repaired by qualified staff only in the event of the following: The point machine has been waterlogged. The point machine is damaged. The point machine has been operating for ten years. The point machine is in a severely neglected state or showing signs of excessive wear. The point machine has reached its service life of 106 throwing operations. The following components must be exchanged each time the SIMAX S700 K electric point machine is repaired, independent of their apparent state: ball spindle drive with transmission clutch as described in Section 8.2.3.4 contact assembly as described in Section 8.2.3.9 limit switches as described in Section 8.2.3.11

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8.2.1 Technical Information relating to Repair Work
The sections below generally describe how to remove various components. To replace them, carry out the same steps in reverse.

CAUTION Before replacing the components, make sure they are free from contamination, surface damage and other defects.

Before assembling new gear wheels, treat them with Molykote paste. Apply a thin layer of type G Molykote paste. Rub in the paste thoroughly. Wipe away any excess with a cloth. Parts and surfaces not coated with lacquer or galvanised must be treated as follows: Grease all the parts and any surfaces before assembling them. For this, use Molub-Alloy 243 Arktik grease. Greasing of parts is understand to be the application of a thick layer of appropriate grease.

8.2.2

Tools and Materials


The following materials are required in addition to the detergents, lubricants and paints specified in Section 3.6: Fluid Plast sealing compound split pins (for technical data see the relevant section) washers (for technical data see the relevant section) nuts (for technical data see the relevant section) bolts/screws (for technical data see the relevant section) You need the following tools: plastic hammer cross head screwdriver folding rule or similar measure writing materials

8.2.3
8.2.3.1

Removal and Fitting of Components


Remove Three-phase Motor Detach the cable harness from the contact assembly and voltage cut-off switch.

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Remove the clamping bolt on the latch lever and demount the rodding to the cut-off switch. Undo the four bolts holding the motor. These fastening bolts are accessible from the outside of the housing. Now you can remove the motor.
1 2 3 4 5

1 2 3

latch lever clamping bolt rodding to cut-off switch (crank handle latch)

4 5

three-phase motor fastening bolt for motor

Fig. 12

Assembly drawing of the motor

If you need to exchange gear wheels, treat the new wheels with Molykote paste. Do not grease the gear wheels until the point machine has been run in (see Section 8.3). 8.2.3.2 Remove and Fit Point Detector The point detector consists of a pair of detector slides and the guide sleeve.

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1 2 3 4 5 6 7

1 2 3 4

gasket grease chamber guide sleeve fastening bolt for point detector

5 6 7

sealing surface cheese head screw pair of detector slides

Fig. 13

Assembly drawing of the point detector

First undo the cheese head screw which acts as a stop preventing the detector slides from being pulled out. The cheese head screw can only be undone if a point machine for left-hand operation is in the "out" position and a point machine for right-hand operation is in the "in" position. Using the crank handle, move the point machine to a position in which both keep-and-detect slides are pushed back. In this position you can pull out the pair of detector slides. If you wish to remove both the guide sleeve and the detector slides, first undo the fastening bolts of the point detector. If you exchange the guide sleeve, you must insert a new gasket. Fill the grease chamber first. Before mounting the point detector, do the following: Clean the sealing surfaces of the guide sleeve and guide flange. Apply a plastic sealing compound, e.g. Fluid Plast from Teroson (Fluid D) in the form of a bead approx. 3 mm thick, to the sealing surface. After bolting on the sleeve, remove any excess compound.

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1 2 3

1 2 3

detector slides control notch pointer

Fig. 14

Assembly drawing of the pointer

Grease the detector slides thoroughly before mounting them. They must be easy to move when the keep-and-detect slides are pushed back. Adjust the guide sleeve correspondingly. If the pointer for the adjusting device has been removed, proceed as follows when fitting it: Set the point machine and the detector slides to the out (extended) position. Pull out the lower detector slide as far as the stop on the keep-and-detect slide. Bolt the pointer in this position so that it coincides with the corresponding edge of the control notch.

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8.2.3.3 Exchange Guide Flanges
1 2 3 4 5 3 6 7

1 2 3 4

throw bar gasket fastening bolts for guide flanges grease chamber

5 6 7

guide flanges fastening bolt for cover cover

Fig. 15

Assembly drawing of the guide flanges

Detach the point detector as described in Section 8.2.3.2. If there is no point detector, unscrew the cover and gasket. Unscrew the cover and stop on the guide flange opposite the point of application of the throw rod (at the unused end of the throw bar). Undo the three remaining fastening bolts and then remove the guide flanges. If you exchange a guide flange, you must insert a new gasket. Fill the grease chamber first. Before mounting the guide flanges, do the following: Clean the sealing surfaces of the guide flanges and machine housing. Apply a plastic sealing compound, e.g. Fluid Plast from Teroson (Fluid D) in the form of a bead approx. 3 mm thick, to the sealing surface.

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Movable bearing of guide flange

Static bearing of guide flange

Sealing compound

Fig. 16

Sealing the guide flange

After bolting on the flanges, remove any excess compound. 8.2.3.4 Remove and Fit Ball Spindle Drive with Transmission Clutch Move the point machine to the mid-way position using the crank handle. Dismount the three-phase motor as described in Section 8.2.3.1.

NOTE Place the three-phase motor beside the point machine or in a stable position over the free corner of the machine housing (see Fig. 17); then you will not have to disconnect the internal wiring.

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1 2 3 4 5

11 10
1 2 3 4 5 6 guide flange compression spring retention clutch detached three-phase motor throw bar wedge

98 7 8 9 10 11

ball spindle clamp ball spindle nut transmission clutch hexagon end piece

Fig. 17

Assembly drawing of the ball spindle drive

Remove the guide flange opposite the transmission clutch as described in Section 8.2.3.3. Press the throw bar against the pressure of the compression springs towards the keep-and-detect slides and secure this position with a wedge. This way you prevent the retention clutch from becoming misaligned with respect to the ball spindle drive.
1 2 3 4 5 67 8 9

1 2 3 4 5

hexagon end piece transmission clutch ball spindle sleeve ball bearing

6 7 8 9

washer tab washer groove nut static bearing of guide flange

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Fig. 18 Assembly drawing of the ball bearing

Next remove the ball bearing with the sleeve: Press the tab of the tab washer out of the groove of the groove nut using a screwdriver. Undo the groove nut. To do this, hold the ball spindle by the hexagon end piece in front of the transmission clutch. Press out the ball bearing by turning the ball spindle. Pull off the ball bearing. When the bearing beside the transmission clutch is free, lift the transmission clutch and pull the ball spindle up at an angle to remove it from the point machine. When doing so, you may have to turn the ball spindle nut to alter its position. When fitting the ball spindle drive, make sure the carriers of the shifting plate engage with the two notches of the clamps of the ball spindle nut. 8.2.3.5 Remove Bearing of the Ball Spindle Static bearing: Follow the instructions in Section 8.2.3.4. Movable bearing: Undo the groove nut in front of the ball bearing and then pull off the ball bearing.

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8.2.3.6 Remove and Fit Keep-and-Detect Slides

2 3 4 5 6 7 8 9

10
1 2 3 4 5 retention clutch guide plate locking piece washer shim 6 7 8 9 10 detector slides throw bar keep-and-detect slide shifting plate compression spring

Fig. 19

Assembly drawing of the keep-and-detect slide

Using the crank handle, turn the point machine to a position in which both keep-and-detect slides are pushed back. Pull out the detector slides until the keep-and-detect slides are free (observe Section (8.2.3.2). Unscrew the guide plate above the keep-and-detect slides and remove the locking pieces, shims and washers from the keep-and-detect slides. Press one keep-and-detect slide back against the compression spring. Swing it up to remove it. Proceed in the same way to remove the second keep-and-detect slide.

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CAUTION The keep-and-detect slides are spring-loaded.

Prior to mounting, grease all parts and surfaces thoroughly. When fitting the keep-and-detect slides, perform the same steps in reverse. 8.2.3.7 Remove and Fit Throw Bar and Retention Clutch Remove the keep-and-detect slides as described in Section 8.2.3.6 to take away the spring pressure on the clutch housing. Remove the lead seal on the retention clutch. Then undo the capstan-head screws and remove the sealing plug.

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1 2 3

4 5 6 7 8 9 10

13 12 11

1 2 3 4 5 6 7
Fig. 20

sealing plug capstan-head screw tension nut retention spring latching bolt clutch housing roller

8 roller bolt 9 throw bar 10 clamp 11 shifting plate 12 keep-and-detect slide 13 detector slides

Assembly drawing of the throw bar and retention clutch

Measure distance "a" (see Fig. 20) and make a note of it. Undo the tension nut and remove the retention spring and latching bolt. Unscrew the cover and then pull out the throw bar. If there are washers in between the tension nut and retention spring (max. 2), be sure to replace them when reassembling the parts to ensure the point machine is secure. You can remove the clutch housing by swinging it round the ball spindle drive. The ball spindle drive does not have to be detached. Before reassembling the parts, fill the grease chamber in the roller. Treat the roller bolt and latching bolt with Molykote paste before greasing them. Also grease the guide hole and adjusting thread of the tension nut.
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When mounting the clutch housing, make sure the shifting plate engages with the notches of the clamps (see Fig. 20). Replace the retention spring with plenty of grease and turn the tension nut as far as the recorded distance "a". Then seal the retention clutch with leads. Grease the throw bar, and particularly the three notches, thoroughly before fitting it. The throw bar must move easily after the guide flanges have been secured. 8.2.3.8 Remove Cover Lock

1
2 3

5 4

1 2 3
Fig. 21

cover of lock washer fastening bolts for cover lock

4 5 6

fixing plate split pin locking bracket

Assembly drawing of the cover lock

Release the split pin and remove the locking bracket.

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CAUTION When fitting the lock, use a new split pin 1.6 x 12 DIN 94-St.

Undo the four fastening bolts holding the lock on the inside of the cover.

CAUTION When doing so, the cover of the lock, the washer and the fixing plate also come off.

8.2.3.9

Exchange Contact Assembly Disconnect the wires from the assembly and undo the fastening bolts.
1 2 3 4

1 2 3 4

fastening bolt insulating plate snap switch operating lever

Fig. 22

Assembly drawing of the contact assembly

No readjustment is necessary after exchanging the contact assembly.

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8.2.3.10 Remove Voltage Cut-off Switch The first step is to detach the voltage cut-off switch physically from the motor: Remove the clamping bolt on the latching lever (see Fig. 13). Demount the rodding to the voltage cut-off switch. Remove the hood. Undo all terminals. Undo the two fastening bolts and remove the voltage cut-off switch. 8.2.3.11 Exchange Contact Assembly with Switches V25124-Z1-A9 for Contact Assembly with Switches V25124-Z1-A19 Follow the instructions below, if you need to exchange the contact assembly. Exchanging the contact assembly Detach the cable harness from the switches. Undo the collar screws from the guide plate and remove the contact assembly. Insert the new contact assembly in the same place and fix it with the collar screws.

1 2
Fig. 23

Collar screws Guide plate


Installing a new contact assembly

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Connect the cable harness according to the terminal connection diagram.

1 2 3 4
Fig. 24

Motor Jumpers Contact assembly with snap switches Cut-off switch with terminal strip
Terminal connection diagram

1
Fig. 25 Circuit diagram

Red jumper wire

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Stick the adhesive label Z25753-B2-X-*-7605 on the existing circuit diagram in the cover.

1
Fig. 26

Adhesive label
Position of adhesive label

Select the type labels with the new Siemens code numbers (SCN) from the table and stick them below the existing type label (inside and outside). S700K (old) C25106-A141 S700K (new) C25106-A141 -A7 -A8 -A141 -A142
Table 2

-A163 -A164 -A165 -A166


Old/new Siemens code numbers for type labels

1 2
Fig. 27

Type label C25106-A141-C469 For 3 block of SCN, see table


Type labels
rd

Check the internal wiring after having exchanged the contact assembly.

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Checking the internal wiring Carry out a continuity test in different point machine positions according to the circuit diagrams shown below. Check that the colours are connected to the corresponding terminals in accordance with T25751-A206-A1-*-2.

Red jumper wire

Fig. 28 Throw bar in for left-hand version, throw bar out for right-hand version

Continuity Test connection 1-5 1-6 3-8 2-8 2-3 4-7 Table 3 Resistance approx. 8 O approx. 8 O approx. 8 O approx. 8 O approx. 16 O <1O Test section 1-2 1-4 2-4 1-ground 2-ground 4-ground

Shunt Resistance > 2 MO > 2 MO > 2 MO > 2 MO > 2 MO > 2 MO

Throw bar in for left-hand version, throw bar out for right-hand version

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Red jumper wire

Fig. 29 Throw bar in mid-way position for left-hand and right-hand versions

Continuity Test connection 1-2 1-3 1-8 4-7 5-6 Resistance approx. 16 O approx. 16 O approx. 8 O <1O <1O

Shunt Test connection 1-5 1-4 4-5 1-ground 4-ground 5-ground Resistance > 2 MO > 2 MO > 2 MO > 2 MO > 2 MO > 2 NO

Table 4

Throw bar in mid-way position for left-hand and right-hand versions

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Red jumper wire

Fig. 30 Throw bar out for left-hand version, throw bar in for right-hand version

Continuity Test connection 1-3 1-8 3-8 2-5 2-6 4-7 Table 5 Resistance approx. 16 O approx. 8 O approx. 8 O approx. 8 O approx. 8 O <1O

Shunt Test connection 1-5 1-4 4-5 1-ground 4-ground 5-ground Resistance > 2 MO > 2 MO > 2 MO > 2 MO > 2 MO > 2 NO

Throw bar out for left-hand version, throw bar in for right-hand version

Check the correct functioning of the switching contacts SA1 to SA8 with the voltage cut-off switch.

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Checking the throwing direction and correspondence of point position and indication Connect the modified point machine to the 4-wire, three-phase AC point circuit of the point interface module in accordance with the specifications in the project documentation. Carry out an identity check of the cable wires between interlocking (point unit/point interface module) and the point machine connected using appropriate test methods and measuring instruments before commissioning the point machine with linked points. Then perform the tests described in the following (with end position detector, if any). Electrically reverse the points three times. Check that the point machine moves properly in the correct direction. Check the correspondence between point position (outdoor site), display on the monitor and indication on the point interface module in the two end positions. Check that a throwing movement already initiated can be reversed at any time and from any position. Simulate trailing of points from the two end positions by turning the motor pinion. Point trailing must be indicated on the point interface module and the monitor.

8.2.3.12

Remove and Fit Limit Switches Remove the voltage cut-off switch as described in Section 8.2.3.10.

1 1 2

4 5

2 3 4 5

3 shaft bar limit switch

rodding to crank handle latch fastening bolt for limit switch

Fig. 31

Assembly drawing of the limit switch

Release the locking washer and pull the shaft out sideways. Release the locking washers on one side and pull the bars out sideways.
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Undo the fastening bolts. Remove the limit switches. When fitting the limit switches, perform the same steps in reverse.

8.3
8.3.1

Final Work
Run In the Point Machine
After exchanging mechanical parts, you need to run in the point machine. Connect the point machine to the rated voltage and perform four running-in cycles. A running-in cycle comprises 8 s running and 4 s break.

8.3.2

Add Inspection Stamp


Record the inspection by adding an appropriate stamp in the housing next to the snap switches.

8.4

Testing after Maintenance and Repair Work


The point machine must conform to the equipment design documents, i.e. be free from contamination, surface damage and other defects. It must be taken for granted that the parts have been fastened with the tightening torques prescribed.

8.4.1

High-Voltage Test
Carry out a high-voltage test before performing the running-in. All currentcarrying parts must be tested with respect to each other and to ground with 2500 V, 50 Hz (routine test). After you have carried out a function check-out and equipped the point machine with all parts, e.g. a point detector, test the forked connection pieces of the detector slides to ground and see whether they have the dielectric strength required (high voltage 2500 V, 50 Hz, test time 1 s).

8.4.2
8.4.2.1

Function Check-out
Test Voltage Set the test voltage in accordance with the table shown below. The voltage must only fall below this value for a short time when the point machine starts to move.

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8.4.2.2 Retention Force By retention force is meant the force that retains the throw bar in the home positions. It is greater than the maximum throwing force. The retention force is not measured directly but depends as a function of the point machine's design on the size of the trailing resistance. It can be determined from the trailing diagram if required. 8.4.2.3 Trailing Resistance By trailing resistance is meant the resistance the point machine applies in the end position to counteract a force acting as a tensile or compressive force on the throw bar until the retention force is overcome and the retention clutch disengages. The throw bar leaves the end position. In the two end positions of the point machine, apply a continuously rising force onto the throw bar until the retention clutch disengages and the throw bar is no longer retained. The maximum force required for this corresponds to the trailing resistance as given in the table below. 8.4.2.4 Throwing Force By throwing force is meant the force acting as a tensile or compressive force on the throw bar while the point machine performs the throwing of the points without any slipping of the transmission clutch. The test is performed at a line resistance of 0 O. Set test load 1 in accordance with the table below. The point machine must move from both end positions to the other end position related without a slipping of the transmission clutch. With test load 2, the point machine must not reach any of the two end positions and the transmission clutch must slip. 8.4.2.5 Blocking Blocking is understand to be a process in which the movement of the throw bar is mechanically hindered and the transmission clutch slips. If the throw bar is blocked in a position unlike the end position, a change in direction must be performed at least once and max. three times in each direction. The throw bar is blocked e.g. in the mid-way position and the direction of rotation of the motor reversed several times so that the transmission clutch slips alternately in both directions of rotation. When doing so, the retention clutch must not disengage.

8.4.2.6

Throwing Time and Running Current By running current is meant the current that can be measured during the throwing process after the peak starting current descended. By throwing time is meant the time the point machine requires from the switch-on of the operating voltage to contact changeover in the other end position. Set the line resistance and test load 3 in accordance with the table below. The point machine must reach both end positions within the throwing time specified in

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the table below. The running current specified in the table must only be briefly exceeded when the point machine starts to move. The running current is independent of the direction of rotation of the motor.
1 Point machine version 2 Thr. stroke 2 3 Trailing resistance 4 Test voltage [AC] Throw. force with test load 1 kN 5.2 5.2 5.2 5.2 7.7 5.2 5.2 5.2 3.7 5.2 5.2 3.5 5.2 7.7 3.7 5.2 5.2 5.2 5.2 5 Throw. time at 0 line resistance s 5.5 4.5 4.5 5.5 6.0 5.5 5.5 5.5 3.0 5.5 5.5 3.0 5.5 6.0 3.0 5.5 4.5 5.5 5.5 Throw. force with test load 2 kN 5.9 5.9 5.9 5.9 8.8 5.9 5.9 5.9 4.4 5.9 5.9 4.5 5.9 8.8 4.4 5.9 5.9 5.9 5.9 kN 4.5 4.5 4.5 4.5 7.5 4.5 4.5 4.5 3.0 4.5 4.5 3.0 4.5 7.5 3.0 4.5 4.5 4.5 4.5 6 Throwing time at line resistance with test load 3 s 6.0 5.0 5.0 6.0 6.5 6.0 6.0 6.0 3.2 6.0 6.0 3.2 6.0 6.5 3.2 6.0 5.0 6.0 6.0 54 54 54 54 45 54 54 54 45 54 54 45 54 45 45 54 54 54 54 7 Running current

mm A3 A10 A11...A16 A19...A24 A27...A34 A35...A36 A37...A38 A39...A42 A43...A44 A45...A48 A49...A50 A51...A52 A53...A56 A59...A62 A63...A64 A65...A66 A67...A68 A69...A70 A73...A74 A75...A76 220 150 150 220 220 220 220 220 220 220 220 220 220 220 220 220 150 220 220

kN 9+0.5 9+0.5 9+0.5 9+0.5 n. trail.* 9+0.5 n. trail.* 9+0.5 9+0.5 9+0.5 9+0.5 9+0.5 n. trail.* n. trail.* 9+0.5 9+0.5 n. trail.* 9+0.5 n. trail.* Table 6

V 380 380 380 380 380 380 380 380 380 380 220/380 380 380 380 380 380 380 380 380

A 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Test values

1. Point

2. Throw-

3. Trailing

4. Test

5.

6.

7. Running

Throwing Throw. time Throwing Throwing time at

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machine version ing resistance voltage stroke mm kN V force with at 0 line force with test load 1 resistance test load 2 kN s kN line resistance with test load 3 kN s current A

Table 7

Empty table for recording the values measured during the function check-out

8.4.2.7

Sealing Retention clutch Finally seal the retention clutch with leads. Non-trailable point machines must have a label on the retention clutch indicating that the point machine is not trailable and the nominal value of the throwing force. Transmission clutch The locking plate must be pressed into a notch of the adjusting screw. Seal the locking screw of the transmission clutch with lacquer.

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Adjusting device for detector slides After fitting the detector slides, check their operation. Move the point machine and detector slides to the in (retracted) position. Push the upper detector slide in as far as the stop on the keep-and-detect slide. In this position the corresponding edge of the control notch must coincide with the edge of the pointer (see Figs. 32 and 33).

P ointer

C ontrol notch

C ontrol notch

P ointer

Fig. 32

Position of the pointer at 160 mm detector slide stroke

P ointer

C ontrol notch

C ontrol notch

P ointer

Fig. 33 Position of the pointer at 68 mm to 90 mm and 98 mm to 119 mm detector slide stroke

8.4.3

Test Stamps and Test Records


Add test stamps to those point machines meeting all testing conditions outside and inside near the type plate.

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Prepare test records and measurement diagrams if required. The direction arrows (A, B) specified in the test record are shown in Fig. 34.
Test set

B
Motor

Terminal strip Applicable to right-hand and left-hand mounting


Fig. 34 Test configuration for function check-out

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