SERVICE MAN.UAL 4551-F~.

Transcription

1 WABCCJ ~ PN-150P PLUG-IN POWER TRANSFER RELAYS (4-POINT) PC. NO. SERIES N , N SERVICE MAN.UAL 4551-F~. CONTENTS Section I II III IV v VI VII VIII IX x XI XII GENERAL.INFORMATION ARMATURE AIR GAP ADJUSTMENT PERMANENT MAGNET INDICATOR CONTACT ADJUSTMENT CALIBRATION SERVICE TESTS CHECK OF CONTACT OPENINGS PERMANENT MAGNET HOLD DOWN FORCE CONTACT RESISTANCE RELAY INDEXING PARTS LIST ' Page November, 1980 A ,,.... t&~... UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD.. INC. C'. ~= I' - I""'\ A A,:-,...,... I""\

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3 WABCD ~ PN-lSOP PLUG-IN POWER TRANSFER RELAYS (4-POINT) - -.PC: NO. "'SERIES N , N SERVICE MANUAL 4551-f CONTENTS Section Page I GENERAL INFORMATION 1 ) II III ARMATURE AIR GAP ADJUSTMENT PERMANENT MAGNET 1 1 IV INDICATOR 1 v CONTACT ADJUSTMENT 2 VI CALIBRATION 6 VII VIII SERVICE TESTS CHECK OF CONTACT OPENINGS ~ "'rl IX PERMANENT MAGNET HOLD DOWN FORCE 8 x CONTACT RESISTANCE 10 XI RELAY INDEXING 10 XII PARTS LIST 11 ' ) November, 1980 A UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC. C\,! F"'\A,4r"".. ". ~.,...

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5 I. GENERAL INFORMATION UNION SWITCH & SIGNAL W :> The PN-lSOP power transfer relays have the same basic structure as the PN-lSOB relays covered in Service Manual SM4551*. They are basically d c relays with a built-in rectifier which enables them to be operated on a c. All calibration should be made using an a c source. The rectifier mounted on the contact block was used in the original factory calibration. Relays should be removed and sericed in accordance with this specification when the drop-away value drops below 90% or the pick-up value rises above 110% of the new relay values. II ARMATURE AIR GAP ADJUSTMENT Refer to Service Manual SM4551, except that the air gap values are as follows: Relay Air Gap 4-Point III. PERMANENT MAGNET Refer to Service Manual SM4551, except use the following adjustment spacers: 4-Point Relay - Use a spacer thick. Spacer thickness may be varied at ±0.010" to meet calibration limits. IV. INDICATOR Refer to Service Manual SM4551. *Refer to the "SU" number when the "SM" number is not currently available. Early "SU" service. specifications are being revised and called "SM", service manuals. The original number is retained. SM4551-Fl, p. 1

6 ~ UNION SWITCH & SIGNAL. : v. CONTACT ADJUSTMENT 5.1 GENERAL The fingers supporting the contact springs should be straight and approximately at right angles to the relay base. Adjustments of contacts should be made using contact adjusting tool N (Dwg. B ). Because of the effect of the weight of the contact tips, all checks of contact adjustment should be made with the relay in the normal upright position. Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive loading or an accidental short through the contacts. In case contacts must be redressed, nothing coarser than a #6 pillar file shoud be used and this should be followed by the use of Metallographic paper to remove file marks "'> After the contacts are filed and/or after adjustments have been made to meet calibration requirements, clean the contacts in accordance with the instructions in Service Specification SU Heel Contact Springs 3 2 Original Design New Design Fig. l Heel Contact Springs Original Design Before adjusting the heel springs it should be determined that dimensions of 0.094"-0.100" exist as shown in Figure 1 for outside to outside across the flats of the depressions of the heel springs where the round pins of the operating arm rest. If they need adjusting, it must be done by bending the springs at the outer ends. After this adjustment it must be determined that the springs are pressing against each other at the two points indicated on Figure 1 and that the free ends are aligned within 1/64 of an inch New Design Before adjusting these heel springs it should be determined that the dimensions exist as shown in Figure land that the SM4551-Fl, p. 2

7 UNION SWITCH & SIGNAL UJ end spring has a slight trapped pressure against the main member. 5.3 Specific Adjustment Contact adjustment shall be performed in the manner described below: Use the nominal spacers called for in Table 1 and adjust front contacts~ de-energize the relay and remove the operating arm by slightly compressing the extreme front end of the heel spring and hold it clear from all heel springs. Adjust the heel spring members at the reduced section so that there is from 0.005" to 0.010" clearance between the front contacts and heel contact tips. Replace the operating arm and work the armature by hand a few times to.,.get the operating arm into its normal operating position; then, check front contact adjustment. After adjusting back contacts, using nominal spacers again remove the operating arm and determine that the heel contacts have at least 0.005" opening at the front and back contacts. A check must be made that when the front contacts are just touching, the back contacts have at least 0.020" opening. When the armature is in the fully released position, the front contacts must have at least 0.050" opening. 5.4 Stick Contact Adjustment (Refer to Table I) A standard low voltage contact has been added at 2F, 2H base terminals of this relay for stick circuit use only. It is recommended to be used in service. The stick contact of this relay is designed to open slightly in advance of the other contacts. The purpose of this advance opening is described below under typical circuit application. CAUTI-ON EQUIPMENT DAMAGE MAY RESULT if the stick contact is employed for any purpose other than its intended use. SM4551-Fl, p. 3

8 OJ UNION SWiTCH & SIGNAL 5.4.l Typical Circuit Application The PN-lSOP Relay is made with one contact adjusted to open slightly in advance of the others. This contact is marked "S" in the circuit diagram of Figure 2 (marked 2F-2H in Figure 3}, and is for the purpose of making the relay adaptable to a special stick circuit designed to eliminate one type of difficulty that is common to all power transfer units. This difficulty occurs under certain conditions, such as high resistance in the ac system, in fuse or wire connections, or poor regulation of the transformer supplying the ac load, which might permit the ac voltage to rise sharply as soon as the load is removed by the opening of the front contacts of the PN-lSOP Relay. This would cause an intermittent opening and closing of the contacts which would be unsatisfactory both as to indication of the signals and service of the contacts. The special stick circuit as shown in Figure 2 is so arranged that when the cgntact marked "S" opens, the circuit of the relay is opened so that it drops regardless of any changes which may occur in the ac voltage thereafter. After the relay has dropped, the load will be supplied by the standby source of power until the crossing relay or track relay which applied the voltage to the load, has picked up to stop the display of the highway crossing indication. The picking up of the control relay provides a pick-up circuit for the PN-lSOP Relay. 5.5 CONTACT BLOCK Wiring of contact-block is shown in Figure 3. Refer to Service Manual SU4551 when replacing the contact block. SM4551-Fl, p. 4

9 UNION SWITCH & SIGNAL ID XR... r- --, BATTERY I I Ac :I I AC,fA.. I, )f,. :, ' c+ ( " c-,, :, I OR X'I'PR l+a -A I ==- BX OR B 2H I NX OR N TO LIGHTS N NX Figure 2, Typical Circuit Application of PN-lSOP Power Transfer Relay in Highway Crossing Scheme Utilizing Special Stick Circuit. Sl Fl, p. 5

10 UNION SWITCH & SIGNAL ':::,,-," INTERNAL, RECTIFIERi---iH J. )I '11t. I ~ >---- I'..,.~ I ""y ' I I I I ~ r---:..---' I c::::j: CJ I c- : 2F IF L--H-t::!:.r' CJ: CJ, c 2H: '" l-tl:j CE)J c::::::j AC AC 18 c::::j c::::::t c::::::t 6F!SF 4F c::::::t c::::j c::::::t 6H!SH 4H c::::::t c::::j c::::::t NOTE! CONTACTS SHOWN ARE FOR 4-POINT RELAY 2F-2H STICK CONTACT Figure 3 - Wiring of Contact Block i~ -- t ~--..::r,,-..,, = ~ ;.;;. ;;;:;;.-...cg. 1-l Rectifier Figure 4. Arrangement of Rectifier on Contact Block VI. CALIBRATION After the relays have been inspected and adjusted, they should be calibrated using a 60 cycle a c source. Figure 5 illustrates the test circuit. SM4551-Fl, p. 6

11 UNION SWITCH & SIGNAL Q) EXTERNAL JUMPERS r-;:;--a -8 c- C+ 2' la IF IH AC AC II 6F SF 4F I 6H SH ;_J REAR OF MOUNTING SASE APPROXIMATELY 20VAC Figure 5. Test Circuit The calibration shall be obtained by adjusting the coil spring to meet the approximate requirements outlined in the tables. The adjustable shunt should then be bent out if necessary to obtain approximately 280 grams hold down force measured at the bottom of the operating arm. Reset the coil spring to give a pick up very close to, but no higher than the value_given in the table. If the relay does not meet the calibration value, readjust the shunt to give a hold down f9rce between the limits in Table 1 and change the contact spacers. All relay adjustments normally can be made by adjusting the coil spring and/or contacts within the allowable limits. If this cannot be done and it appears that the rectifier (Pc. No. UN341859) is faulty, replace it with a new one Drop-Away The relay shall be energized up to, but no higher than the normal voltage and the current then gradually reduced until the armature stop pin starts to move away from its pole piece. It shall be checked that at this value the armature completes its downward motion opening all front contacts and closing all back contacts. The current shall be further reduced gradually and a check made that the back contacts are fully compressed at not less than the value specified in the calibration table under heading "Full Back Contact Pressure Drop-Away". The following information is supplied to further explain and define the calibration of the PN-lSOP relay. SM4551-Fl, p. 7

12 ffi UNION SWITCH & SIGNAL 6.2 Pick-Up and Working Immediately after the drop-away value has been measured, reduce the current to zero. Open the circuit for one second and again apply current; gradually increasing it until the armature moves away from the permanent magnet with a definite sudden motion. The voltage at which this occurs should not be more than 95% of the actual pick up value measured on the tested relay. If it is, reduce the magnet hold down force by moving the adjustable shunt closer to the magnet within allowable limits and/or increase the spacer for adjusting the back contacts. Continue increasing the current until the armature picks up to close the front contacts moving to the stop pin at the same energization. The voltage at which this occurs should not be more than that specified in the calibration tables for Pick Up and Working., ~ > VII. SERVICE TESTS Refer to Service Manual SM4551 except per Tables 2 and 3 of this specification. Type PN relays must be inspected and tested at least every two years. The tests and inspections are to include: pick-up current, drop-away current, timing of slow operating and timing relays, visual inspection of contacts for damage or misalignment, corrosion or other contamination of parts, loose parts in cover, broken seal, and cracked or broken cover. Type PN relays installed in locomotive or car-carried equipment are to be inspected and tested at least every two years as above. In addition, every four years the relays are to be removed from service, and adjusted, repaired and tested. Relays not passing the above-stated tests and inspections must be replaced and not returned to service until the operating characteristics and conditions are in accordance with US&S specifications." VIII. CHECK OF CONTACT OPENINGS Refer to Service Manual SM4551. IX. PERMANENT MAGNET HOLD-DOWN FORCE Refer to Service Manual SM4551, except apply a minimum force of 250 grams on the 4-point relay. Refer to Table 1. SM4551-Fl, p. 8

13 Test No. TABLE l -- ADJUSTMENT AND CALIBRATION SUMMARY FOR PN-150P POWER TRANSFER RELAYS 4 Point Relay Stick 2F Nominal Min. Max. Cont. 2H Remarks 1.. 2,a Permanent Magnet Main Stop-Pin Spacer for Assembly 0.145" 0.135" 0.155" Nom Min Back stop-pins Touching.., Front Contact Main Stop-Pi~ Spacer.!Adjustment 0.053" 0.048" 0.058" Contact Just Open Adjustment. b Front Contact Main Stop-Pin Spacer. Adjustment 0.048" 0.043" 0.053" Contact Must Close a b c 6, 7. 8, ''t.s 11. Back Contact Main Stop-Pin Spacer. Adiustment 0.081" 0.086" --- Contact Just Open. Back Contact Main Stop-Pin Spacer. Adjustment 0.086" 0.091" --- Contact Just Close. -Front Contact Openings " --- With Back Contacts Just -Front Contact Armature Released Against Openings " --- Permanent Magnet. -Front & Back Contact Openings " --- Removed. With Operating Arms Closed. Droo-Awav --- Table --- After Charge. To Close Back Contacts. - Drop-Away to Full Back Contact Pressure --- Table --- Maqnet Break-Away From After Drop-Away, Reduce Current Until Armature Rests on Permanent Of Actual Pick-Up For Break-Away Permanent Magnet % From the Permanent Magnet. Pick-Up and Working Table of Armature Mark Actual Value on Left Side Force on Bottom Contact Engaging Pin Hold-Down of Operating Arm to Pull Armature Torque 250 gms from Permanent Magnet After Charge. Final Electrical Inspection Recheck Tests No. 6 and 9 With Cover Aoolied. c z 0 z i ~ :c " (/) 5 ~,..

14 UNION SWITCH & SIGNAL X. CONTACT RESISTANCE Refer to Service Manual SM4551, except use the following contact resistance values: Ohms Type of Contacts (Front and Back Contacts} Silver-to-Silverimpregnated carbon 10.1 Current Rating XI. o.os HD (Heavy Duty) contacts are rated 15 amperes maximum first range voltage (0-30 volts 4 AC Only.) RELAY INDEXING Refer to Service Manual SM4551. TABLE 3 PN-ISOP (4.,Point) Calibration Values Drop-Awa.y Full Back Maximum Relay Contact Pressure Pick Up and Volts (A-C.) Resistauce Charge Drop-Away Working Ohms Volts (A-C.) MIN. MAX. Volts (A-C.) Volts (A-C.) a SM4551-Fl, p. 10.

15 UNION SWITCH & SIGNAL XII. PARTS LIST (Refer to Figure.6) Item No. 1.., "" ~ Piece Number N M Ml96812 M M J48716 M See Tabulation M J52243 See Tabulation J M M M See Tabulation! M See Tabulation M J J See Tabulation l J50016 J See Tabul;:,,tion J J47081 N J M M A43013 J U52955 Description Frame Rod, Latch Washer Spring, Coil Latch Dowel Pin Spring Armature Washer Ser., tt6-32x7/16 Fil. Stl. Block, Contact Ser., #6-32x3/4 Phillips HD. Mach. Arm-Molded Operating Indicator Lock Nut Ser. - Spring Guide Magnet, Permanent Strap Lock, Bolt Screw Handle Washer, Lock #10 Int. Tooth Ph. Bz. Ser., #10-32x3/8 Phillips Pan Hd. Stl. Cad. Pl. Coil Lock, Coil Ser., l/4-20x3/4 Hex. Cap. Stl. Ser., H4-40x3/16 Rd. Stl~ F. Plate, name Pin, Indexing Gasket Cover Ser., #6-32x3/8 Rd. Stl. Washer Screw Wire, Seal Seal Ordinary Acting Slow Drop-Away Calibration Tag as Req'd M: J See Tabulation Spring, Operating Arm Wash. #6 Shprf. Lk. Spacer, Magnet SM4551-rl, p. 11

16 UNION SWITCH & SIGNAL XII PARTS LIST CONTINUED (Refer to Figu:r::~ 6) Item No Piece Humber M J M i M M M J l J Description Counterweight Seal, Vent lilut, Lock Tag Spacer Plate, Adjustment Ser., ~6-32xl5/16 Hex. Cap Stl. Pin, Roll washer, Plate Block, Cover Fastening SM4551-Fl, p. 12

17 ../ O~SCRIPTION OF KIND CONTACTS COIL AC RELAY OF ) PC. NO. VOLTS STYLE RELAY OHMS lf L.V. ORDINARY UN F & 4B L.V. HD 10 PN-lSOP ACTING 240 UN lf L.V. ORDINARY UN F & 4B L.V. an 12 PN-150P ACTING 400 UN screw for Fastenin Permanent Hagnet Assy. to Pole ~ Piece (See Note J Permanent Hag net Soacer & I SH...t I l erma'len Assembly 1274!? SH. M Contact Block@ be. N4J Arma Lure Assembly N SH. 5 SPEC EU AIR GAP (PARALLEL) SEE SPEC. SH. "A" "B" r '":l! I ' j_ UNION SWITCH & SIGNAL LOCATION OF!40UNTIUG BASE PARTS BAG COMPL. STAHDARO INDEXIHG PINS {FOR REF. ONLY) NAME PLATE WITH PROPER WITH SOLDERLESS ROW (INDEXING PLATE) INDEXING PLATE TYPE RECEPTACLES A B c SH SH. ru:;c.nnt ~R. -,,,,.. -- c::u_ Ui"!~::>J..'!~b-b"lUJ UM SH 64 UN3 "lnf;rl -orn? q 1 UM45.l.4~b-640.l UM SH 64 UN"l"l06R1-080"l q N Gt rr-~---~- -~-- ~ i , r :-~! i, ' , "--- -J -.., ~., r--j---t ; l I I I I I 1 --~ ~---~~~ 1 I I a j ~---~_; ~!' l ~ / \JJ s~cr,on c c Rectifier J726l50-0l23 Contact Block.. :) $o1jer ~ r. Jll 73t 30,1111 W... -Q """..;?fll(;o.. Rl!!GTIFllER. '( ~ -z.~""-- "'... h...& 'J" 45<."'L (cou>e. Co,:, io) I(~ ~had Typieol.!Jo/d rr.n.9 o-f ulni ro eo,,~ W,1t1N l)ta,;//l,111"1 OT u,nt,11cr ljujc11: (In,,,, JI) (All Ltl<ld,0 ~ dr_..d "-~!'./ h fc4le.e.n ll i:+. 4 l"f~ &,,..,._) Figure 6, PN-lSOP Plug-In Power Transfer Relay "4Ta"K"--Y S&AL \1'1,N ~ ova tt VU41' OM OUT ol' owe-. 'ii" ' & 5".., IJ$t!D /IIS "all)1j1'2.&d 1'0 oat... 11,I $TIZOKC Pt!lff Sf"Et!- IU-i.!,/0. _SM4551-Fl, p. 13/14

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19 WABCO ~~ SERVICE MANUAL ADDENDUM :.- > PERIODIC MAINTENANCE All vital relays must be inspected and tested at least every two (2) years. The tests and inspections are to include: pick-up current, drop-away current, timing of slow operating and timing relays, visual inspection of contacts for damage or misalignment, corrosion, or o~her ~ontamination of parts, loose parts inside of cover, broken seal, and cracked or broken cover. All vital relays installed in locomotive or car-carried equipment are to be inspected and tested at least every two (2) years as above. In addition, every four (4) years the relays are to be removed from service and adjusted, repaired and tested. Relays not passing the above stated tests and inspections must be replaced and not returned to service until the operating characteristics and conditions are in accordance with US&S specifications. June, 1979 A-79-3M-2321-AD1 :.''... UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD, INC. Swissvale. PA 15218

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