February, Swissvale, Pa. INSTRUCTION PAMPHLET U-5623-A MASTER RELAY FOR AMPLIFIER FOR UNION CODED CAB SIGNAL EQUIPMENT

Transcription

1 INSTRUCTION PAMPHLET U-5623-A MASTER RELAY FOR AMPLIFIER FOR UNION CODED CAB SIGNAL EQUIPMENT February, UNION SWITCH & SIGNAL COMPANY Swissvale, Pa.

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3 U. S. & S. Co. U-5623-A contact adjustments are outside the limits indicated, the adjustment should be corrected and the heat treatment repeated. Fig. 3 is a schematic view of the relay from the top, showing the nominal values of adjustment of the armature, pole pieces, and contacts. 5. Calibration - With i:he permanent magnet attached and using the circuit of Fig. 4, the relay should be energized at the charge value of 100 ma. and pole changed several times, allowing the current to build up to its full value in each direction. It should be noted that wlth positive voltage applied to the 18 terminal of the relay, the armature goes to the right, closing the right-hand contact. This wm check that the permanent magnet has been applied in the proper direction. POLE CHANGING SWITCH D. C. MILLIAMMETER 100 MA. SCALE ~---, A i Fig Ci:rcuit fo:r Testing Master Relay. In calibrating the rela.v-., ~t should first be charged to 100 ma. The carrent should then be gradually w zero and gradually increased with the opposite polarity until the arm.2j;.1:;:e ::'e.verses. This is the pick-up current and should meet the following limits: Right to LefJ:. 14 ma. ± 0.5 ma. Left to Right 18 ma. ± 0.5 ma. The pick-up value shouid bs taken for both an armature movement from left to right and right to left. When the armature starts to move away from one pole piece, it should continue its travel until it comes to rest against the opposite pole piece. The relay should be adjusted to meet calibration values by adjusting rear pole pieces. In no case shall the rear air gaps from pole piece to armature be less than inch, or more than inch with the armature in that position which provides the smallest air gap. In case pick-up values are too high with rear air gaps at the minimum value, the strength of the permanent :magnet should be decreased. In case the armature will not make a complete stroke at the pick-up value, the magnet strength should be increased.

4 U.S. & S. Co U-5623-A After the relay has been adjusted to meet the calibration values, the armature holding force should be measured by applying a gram gauge to the free end of the armature and measuring the force. required to pull the armatu re away from each pole piece. The force required to pull the armature away from the left pole piece should not be less than 30 grams and the force required to pull it away from the right pole piece should not be less than 25 grams. 6. Breaking-in Run - The relay should now be placed on an operation run for 48 hours at 180 code and at approximately 33 ma., using the suggested circuit shown in Fig. 5. At the conclusion of this run, the calibration should be measured. H it is found that during the breaking-in run the calibration has changed more than 5% or is not within the limits specified in the preceding section, it will be necessary to readjust the relay and repeat the breaking-in run. H any bending of the contacts, springs, or spring stops is necessary, the relay heat treatment must also be repeated. MASTER RELAY #1 LJ ~ MASTER RELAY #2 [g MASTER RELAY #3 [g ;:::- BATTERY -;:::- 12 VOLTS T 25 l CD 15 J- - -}" 25 l co l CD 15 CD 25 } 15 TO OTHER MASTER RELAYS 180 CODE TRANSMITTER CONTACT (MUST BE SILVER-PLATINUM TYPE) Fig Suggested Circuit for Breaking-In Run. IV. FINAL INSPECTION AND TESTS Before the relay is assembled to its cover and sealed, it should be checked to insure that all nuts and screws are tight. All contacts should be examined to see that they are aligned both vertically and horizontally and that they are making squarely. Particular care should be taken to remove any dirt or foreign matter from the relay and cover before they are assembled together. Should any loose iron particles be left inside the relay, they are likely to eventually be drawn into the magnetic field between the two front pole pieces, thus reducing the stroke of the armature. To guard against such an occurrence, all tools used in the assembly and adjustment of the relay should be kept as clean as possible by frequently wiping them with a clean cloth moistened with carbon tetra-

5 ltniou ~tttitr4 & ~igunl <!!ttmpauy SWISSVALE, PA. Subject: MASTER RELAY For Amplifier for Union Coded Cab Signal Equipment Catalog Plate N-llC INSTRUCTION PAMPHLET Number U-5623-A Date February 11, Sheets TABLE OF CONTENTS Page I. General Description n. Maintenance and Inspection tii. Instructions for Shop Repair Relay Assembly Pole Piece Adjustment Permanent Magnet... ; 2 4. Contact Adjustment Calibration Breaking-in Run IV. Final Inspection and Tests V. List of Gauges for Adjustment I. GENERAL DESCRIPTION This relay is a single-point polar-stick type relay designed for operation with low-voltage code amplifiers and so adjusted that its armature will remain in the position to which it was last energized. Thus when positive voltage is applied to the 18 terminal of the relay, the armature will move to close the right-hand contact. When opposite polarity is applied, the armature will move to the left. The relay mechanism consists essentially of a long, thin, narrow armature of high quality magnetic material located on the axis of an operating coil and free at one end to move to right and left between pole pieces in the field of a permanent magnet. Contacts are mounted on an extension of the free end of the armature. The opposite end of the armature is fixed to the supporting bracket through a flat spring hinge. In order to obtain the plug-in feature, the relay is used with the top plate down and when calibrated or operated, the relay should be in this position. See Catalog Plate N-llC. Il. MAINTENANCE AND INSPECTION The master relays in locomotive service should be inspected at regular intervals for proper operation and the condition of the contacts should be observed. The contacts should not show excessive pitting or loss of material, although a small amount of roughening is to be expected and is not harmful.

6 U.S. & S. Co U-5623-A At least once every three years, the calibration values of the relay should be measured. If these values do not fall within the limits shown on Page 7 under "Calibration", the relay should be readjusted in accordance with the procedure hereinafter described. III. INSTRUCTIONS FOR SHOP REPAIR Since the contacts are the only wearing parts in this relay, in most cases the relay can be restored to proper operation by dressing and readjusting them. In such a case, the relay should be readjusted and calibrated in accordance with the procedure outlined in subsequent paragraphs. H for any reason it is necessary to completely dismantle and reassemble the relay, it should be r~assembled in the following manner: 1. Relay Assembly - Catalog Plate N-11C shows the assembled relay and references for the detail parts. First, the coil and magnetic structure should be assembled to the mounting fra-i:ne as shown on the catalog plate. It should be checked that the armature has sufficient clearance to prevent it from binding on the coil spool for any armature position. The relay mechanism and top plate assembly should be completed with the exception of the permanent magnet and its clamping strap which should be applied later after certain other adjustments have been made. The armature should be set to take a free position in the approximate center of the opening. The spring at the base of the armature should be bent only as absolutely necessary to bring the armature into its proper position. 2. Pole Piece Adjustment - The rear pole pieces (those nearest armature hinge spring) should be set first so that the air gap between the armature in its center position and each pole piece is approximately inch. The rear pole pieces should not be locked in place as they may be readjusted in calibrating the relay. The right front pole piece should be adjusted so that the distance from the pole piece to the armature is inch with the armature free. The left front pole piece should then be adjusted for a total armature stroke of inch at the pole pieces. 3. Permanent Magnet - The strength of the permanent magnet can be measured by applying it to the magnet tester, Pc This tester is essentially a master relay magnet structure with a graduated dial by means of which the force in grams required to pull the armature of the tester away from the pole face of the permanent magnet under test can be determined. (See Fig. 1) The permanent magnet should be applied at the front of the testing device, across the. two vertical members or "backstraps" of the magnetic structure, and resting also against the small stop member near the bottom of each backstrap. The north pole of the magnet should be at the left side of the testing device. The north pole is marked "N" in red ink and is that pole of the magnet which attracts the south seeking pole of a magnetic comµtss needle..

7 U.S. & S. Co U-5463-A 0 0 PERMANENT MAGNET \-r I I I I LJ Fig. 1.. Magnet Tester. Starting with the spring at zero on the dial and the armature resting against the left-hand pole piece, the dial should be moved gradually to the right. The spring will indicate the correct "grams" on the dial at the instant when the armature breaks free from the pole piece. Before using this device, it should be checked that with the spring free of the armature and no permanent magnet applied, the spring stands at zero on the dial. This adjustment may be corrected, if necessary, by carefully bending the spring just enough to bring it back to zero on the dial. It should also be checked occasionally that with the spring free of the armature and no magnet applied, the armature stands in such a position. that light is just visible between its core pin and the left-hand pole piece. If necessary, this adjustment may be corrected by pressing a screw driver, or

8 U.S. & S. Co U-5623-A other such implement, against the center rivet at the base of the armature. Only enough pressure should be exerted to bring the top of the armature into its proper position. The permanent magnet used in the master relay is made of Alnico steel, and when properly handled it will retain its magnetic strength indefinitely. If the permanent magnet is removed from a relay for any length of time, it should be protected against loss of strength by a piece of soft iron, or ''keeper'', applied against both poles of the magnet. A permanent magnet should never be dropped or hammered in any way as this tends to reduce its strength. The strength of the permanent magnet when measured on the testing device shown in Fig. 1 should be between 1l and 13 grams. If the strength of the permanent magnet meets these limits, it should be reapplied to the relay magnet structure, first making certain that the pole marked "N" is applied against the left-hand backstrap as shown in Fig. L If the' strength of the permanent magnet does not fall within the limits of 11 to 13 grams, it should first be recharged and then aged on the Magnet Charger, Pc , shown in Fig. 2. To charge the permanent magnet, place it in the position shown in Fig. 2 so that it forms a bridge between the left and center legs of the core. The "N" pole of the permanent magnet should rest on the left-hand leg of the core, i.e., the leg surrounded by the larger of the two coils. Now close the switch DC for approximately one second, then open for one second, repeating PERMANENT MAGNET "" LEFT CORE NOTE:-WHERE ONLY 230 VOLTS D. C. IS AVAILABLE, MAGNET CHARGER PC SHOULD BE USE D. RIGHT HAND (ID...--,e.- CORE LEG ~ CHARGING COIL (LARGE} ~ AGING COIL (small} (ID (ID VARIABLE AUTO-TRANS. 32V. + D.C. 110V. 60"' SWITCH D.C AMPS. A.C. Fig Magnet Charger. SWITCH A.C.

9 U.S. & S. Co U-5623-A until three operations of opening and closing have been made, ending with the switch in the open position. To "age" the permanent magnet, that is, to reduce its strength, it should be shifted to the center and right-hand legs of the core. In the aging operation, the "N" pole of the magnet may rest on either the center or righthand leg of the core. Now proceed as follows: (a) Set the variable transformer to its zero or no-voltage position. See Fig. 2. (b) Close switch AC. (c} Increase the alternating current by means of variable transformer to approximately 4.0 amps. and then slowly reduce the current again to zero. This completes an aging cycle. (d) Measure the strength of the permanent magnet on the tester shown in Fig. 1 and in the manner l)reviously described. If the strength is greater than 13 grams, the aging cycle must be repeated, this time with a somewhat higher value of alternating current. The aging coil, in conjunction with the meter, thus provides a means for measuring the comparative amount of magnetism in the magnet during the calibration process. (e) If during the aging procedure the magnet strength is reduced below 11 grams, the magnet must again be charged to full strength and again aged. The above procedure must be repeated until the magnet strength lies between 11 and 13 grams. To prevent overheating the magnet charger coil or discharging the battery, switch DC should be closed only during the short time required for charging. Switch DC and the wiring between battery and charger must be of sufficient size to carry the required current without excessive voltage drop. 4. Contact Adjustment - If the contacts show evidence of burning or pitting, they should first be dressed with an abrasive strip such as "Rimac Flextone" (Rimak-McLwaine, Inc., 16 Hudson St., New York, N.Y.) and finished by drawing a strip of bond paper between them. Now attach the permanent magnet teml)orarily to the backstraps, making sure that the magnet pole marked "N" is against the left-hand backstrap. As it will later be necessary to remove the permanent magnet, the magnet clamp may be left off for the present. Adjust the spring stops to obtain 2 0 grams initial pressure in each contact spring. Then with the armature held against a inch spacer between the core pin and the right-hand pole piece, adjust the right-hand contact assembly about the center line of the hex. head screw Pc until the contact tips line up and until light is just visible between them. With a inch core pin spacer the contact should be closed. Then tighten screw Pc securely and check that the contact remains in proper adjustment. Repeat the same procedure for the left-hand contact assembly.

10 U. S. & S. Co U-5623-A -j L,, MIN:..._)' MIN. o.01s"max " MAX. "N" POLE OF PERMANENT MAGNET AGAINST THIS BACK STRAP GRAMS PRESSURE Fig Nominal Values of Adjustments for Armature, Pole Pieces, Contacts, and Contact Springs. After the above adjustments have been completed, the relay without permanent magnet) should be heat treated for at least 16 hours at 200 F. After the heat treatment, with the permanent magnet still removed, a check should be made to see that the armature is still centered between the front pole pieces. H there has been a change of the armature from this central position, a corrective adjustment of the front pole pieces should be made as called for under "POLE PIECE ADJUSTMENT". The permanent magnet should now be permanently put back in place and the clamp applied. A check should be made to see that the contact compression has not changed by more than inch and that the initial pressure as measured by a gram gauge is between 19 and 21 grams. In case any of these

11 U.S. & S. Co~ U-5623-A contact adjustments are outside the limits indicated, the adjustment should be corrected and the heat treatment repeated. Fig. 3 is a schematic view of the relay from the top, showing the nominal values of adjustment of the armature, pole pieces, and contacts. 5. Calibration - With the permanent magnet attached and using the circuit of Fig. 4, the relay should be energized at the charge value of 100 ma. and pole changed several times, allowing the current to build up to its full value in each direction. It should be noted that with positive voltage applied to the 18 terminal of the relay, the armature goes to the right, closing the right-hand contact. This will check that the permanent magnet has been applied in the proper direction. POLE CHANGING SWITCH D.C. MILLIAMMETER 100 MA. SCALE A Fig Circuit for Testing Master Relay. In calibrating the relay, it should first be charged to 100 ma. The current should then be gradually reduced to zero and gradually increased with the opposite polarity until the armature reverses. This is the pick-up current and should meet the following limits: Right to Left Left to Right 14 ma.± 0.5 ma. 18 ma.± 0.5 ma. The pick-up value should be taken for both an armature movement from left to right and right to left. When the armature starts to move away from one pole piece, it should continue its travel until it comes to rest against the opposite pole piece. The relay should be adjusted to meet calibration values by adjusting rear pole pieces. In no case shall the rear air gaps from pole piece to armature be less than inch, or more than inch with the armature in that position which provides the smallest air gap. In case pick-up values are too high with rear air gaps at the minimum value, the strength of the permanent magnet should be decreased. In case the armature will not make a complete stroke at the pick-up value, the magnet strength should be increased.

12 U.S. & S. Co U-5623-A After the relay has been adjusted to meet the calibration values, the armature holding force should be measured by applying a gram gauge to the free end of the armature and measuring the force required to pull the armatu re away from each pole piece. The force required to pull the armature away from the left pole piece should not be less than 30 grams and the force required to pull it away from the right pole piece should not be less than 25 grams. 6. Breaking-in Run - The relay should now be placed on an operation run for 48 hours at 180 code and at approximately 33 ma., using the suggested circuit shown in Fig. 5. At the conclusion of this run, the calibration should be measured. H it is found that during the breaking-in run the calibration has changed more than 5% or is not within the limits specified in the preceding section, it will be necessary to readjust the relay and repeat the breaking-in run. Jf any bending of the contacts, springs, or spring stops is necessary, the relay heat treatment must also be repeated =:- BATTERY -=:- 12 VOLTS T MASTER RELAY #t CD 15,_ ')" MASTER RELAY #2 CJ 1 CD 2S CODE TRANSMITTER CONTACT (MUST BE SILVER-PLATINUM TYPE) MASTER RELAY # I C-D IS CD 25 } 15 TO OTHER MASTER RELAYS Fig Suggested Circuit for Breaking-In Run. IV. FINAL INSPECTION AND TESTS Before the relay is assembled to its cover and sealed, it should be checked to insure that all nuts and screws are tight. All contacts should be examined to see that they are aligned both vertically and horizontally and that they are making squarely. Particular care should be taken to remove any dirt or foreign matter from the relay and cover before they are assembled together. Should any loose iron particles be left inside the relay, they are likely to eventually be drawn into the magnetic field between the two front pole pieces, thus reducing the stroke of the armature. To guard against such an occurrence, all tools used in the assembly and adjustment of the relay should be kept as clean as possible by frequently wiping them with a clean cloth moistened with carbon tetra-

13 U. S. & S. Co U-5623-A chloride and then wiping them dry with a clean cloth. The chromium plated surfaces of the front pole pieces and the armature, where it strikes them, should be cleaned by rubbing with a small camel's hair brush moistened with carbon tetrachloride and immediately wiping with a clean dry lintless cloth. The cover should be blown out with compressed air before the relay mechanism is enclosed within it. All parts of the relay, when not being assembled, should be kept in dust-free containers. The assembled relay should be given an insulation test between the various terminals and the case. The insulation resistance should be not less than 50.0 megohms. The relay calibration should be rechecked after the relay is sealed. V. LIST OF GAUGES FOR ADJUSTMENT Thickness in Inches Piece No

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16 PLATE N-1 lc nzlf 15 II S o 0 4" II 4-8 "I.) SECTION "Z-Z" """""" ,...,~ ttW...~~~~~~- 22 LEAD CONNECTION TO PERMANENT MAGNET i :,{lltliil~~====l~'"""'rr:a.~ = ~~l:t"" WIRING DIAGRAM 65 A MASTER RELAY 47

17 PLATE N-llC UNION SWITCH & SIGNAL Co. AUTOMATIC TRAIN CONTROL DETAIL PARTS MASTER RELAY Order by Plate, Piece, Reference and Abbreviated Description Given in Heavy Face Type Only... PIECE REF. DESCRIPTION lj A MASTER RELAY COMPLETE, lf-lb H.V. Contacts DWG.REF. C TOP PLATE C TERMINAL POST WITH SCREW, NUT AND WASHERS (Inc.l-3a, 1-4, 1-5, 1-6 and 1-7) a TERMINAL POST ONLY NUT BOLT LOCK SCREW WASHER TERMINAL POST WITH SCREW, NUT AND WASHERS (Inc.l-3a, 1-4, 1-5, 1-6, 1-7 and 2-9) WASHER TERMINAL POST WITH SCREW AND WASHER (Inc.1-lOa, 1-7 and 1-11) loa TERMINAL POST ONLY SCREW GASKET FRONT SUPPORT BRACKET C REAR SUPPORT BRACKET C MACHINE SCREW, NO x 3/4 in. Rd.Hd.S. (Tin Pl.) with No.10 Pl. S.Lock Washer (1/16 in. x 3/64 in.) (Tin Pl.) and Washer Ref WASHER MACHINE SCREW, NO x 1-1/8 in. Fil.Hd.S. (Tin Pl.) with No.10 Pl.S.Lock Washer (1/16 in. x 3/64 in.) (Tin Pl.) and Washer Ref CONTACT SPRING BOARD SCREW

18 UNION SWITCH & SIGNAL Co. PLATE N-llC -{CONTINUED) PIECE REF. DESCRIPTION DWG. REF. 20 SCREW Ref.20a with No.8 Pl.S.Lock Washer (1/16 in. x 3/64 in.) (Tin Pl.) and Washer Ref a SCREW ONLY WASHER L.H. CONTACT SPRING COMPLETE as shown a R.H. CONTACT SPRING COMPLETE CONTACT BRACKET TERMINAL for Ref , I a TERMINAL for Ref.22a RIVET CONTACT SPRING WITH TUNGSTEN TIP TUNGSTEN TIP.for Refs.26 and CONT ACT SPRING STOP , LEAD COMPLETE B-9991~20 30 SCREW Ref.30a with Washer Ref a SCREW ONLY BOLT LOCK MOUNTING FRAME..... : C SCREW BRACKET MACHINE SCREW, NO x 2-1/8 in. Fil.Hd.S. (Tin Pl.) with No.6 Pl. S.Lock Washer (3/64 in. x 1/32 in.) (Tin Pl.), Nut Ref.36 and Washer Ref NUT WASHER RESISTOR STOP MACHINE SCREW; NO x 5/16 in. Fil.Hd.S. (Tin Pl.) with No. 6 Pl. S.Lock Washer (3/64 in. x 1/32 in.) (Tin Pl.) BOLT LOCK C.N RESISTOR, 300-0hm, 10-Watt BACK STRAP SCREW SCREW

19 PLATE N-llC UNION SWITCH & SIGNAL Co. -(CONTINUED) PIECE REF. DESCRIPTION OWG. REF BOLT LOCK COIL COMPLETE, 30-0hm.s ARMATURE WITH TUNGSTEN TIPS CLAMP PLATE SCREW Ref.49a with No. 4 Ph. Bz. Lock Washer (Int.Teeth) (N.P.) a SCREWONLY PIN PERMANENT MAGNET PERMANENT MAGNET CLAMP SCREW Ref.53a with No. 6 Ph.Bz.Lock Washer (Int.Teeth) (N.P.) , 53a SCREW ONLY CASE C DOOR C GLASS SHIELD GASKET MACHINE SCREW, NO x 5/8 in. Flat Hd.S. (Tin Pl.) for attaching Door to Case (Not shown) NAME PLATE MACHINE SCREW, NO x 3/16 in. Rd.Rd.Br. (N.P.) SPACER LOCKING INSULATION SCREW Ref.53 with Washer Ref WASHER CLAMP PLATE COIL RETAINING SPRING POLE PIECE POLE PIECE LEAD COMPLETE B LEAD COMPLETE B

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