PN-lSOB D.C. PLUG-IN RELAYS (Having Part Number Suffixes Under O 11 )

Transcription

1 SERVICE MANUAL 4551 PN-lSOB D.C. PLUG-IN RELAYS (Having Part Number Suffixes Under O 11 ) Supplementary Specifications: SM-4551-A; PN-150B Biased Track Relay SM-4551-B; PN-lSON, Neutral Relay SM-4551-C; PN-lSOBSR Biased Slow Drop-Away Relay SM-4551-D; PN-150BD, Three Position Relay SM-4551-E; PN-150HD, Heavy Duty Contact Relay SM-4551-F; PN-150P, Power Transfer Relays (2 and 4 contact) SM-4551-G; PP-151, Magnetic Stick Relays SM-4551-H; PN-150B, Biased Quick Shunting Track Relay SM-4551-J; PN-150BL, Biased Light-Out Relay S K; PN-150BC, Biased Decoding Relay Sil-4551-L; PN-150i3E, Biased Eigh Efficiency Relay SM-4551-M; PN-150BM, Magnetic Heavy Duty Contact Relay SM-4551-N; PN-150B, Line Relay SM-4551-P; PN-150BE, Relay for Time Code Control System SM-4551-Q; PN-150BE, For use with UT Timing Units SM-4551-R; PN-150BH, Biased High Drop Away Track Relays SM-4551-S; PN-150NE, Neutral Ordinary Acting High Efficient Line Relay SM-4551-T; PN-150BH, Biased Quick Shunting Track Relay SM-4551-V; PN-150BH, Biased High Drop Away-AC Immune Track Relay SM-4551-W; PN-159B, Biased D.C. Car Carried Relay This service specification covers the necessary information for the adjustment and calibration of PN-150B biased plug-in line relays. March, 1979 D-2/ UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA PRINTED IN USA

2 I. ARMATURE AIR GAP ADJUSTMENT On relays with 6FB contacts, the armature is set at the factory to a parallel air gap of O. 023 inch. Safety stop pins must not touch the pole faces. II. PERMANENT MAGNET A. General These magnets are of a special alloy that permits retention of proper strength indefinitely if not abused. When not in place on relays, magnet assemblies should be kept separately with the screws tight which hold the shunt and extension to the magnet. These screws should never be loosened sufficiently to let the shunt be separated from the magnet even when on the relay as this would weaken the magnet considerably. Should a magnet become weakened, we suggest that it be returned to our factory for recharging due to the special equipment required to charge the magnet fully and then age it to its best working strength. The polarity of the magnet should be such that the top (end farthest from the two notched holes) will attract the end of a compass needle which points toward geographic south. B. Assembly The magnet assembly should be applied to the pole piece as shown in Fig. I making sure that the shunt between the magnet and the magnet extension is touching the pole piece. Tighten the two long screws holding the magnet assembly to the pole piece sufficiently to straighten the curved strap against the magnet. Bend the nut locks securely up against the sides of the screw heads. MAGNET ADJUSTABLE SHUNT MAGNETIC SHUNT POLE PIECE MAGNET EXTENSION ii PHOSPHOR BRONZE OR STEEL SCREW AS REQUIRED Fig. l... Assembly of Permanent Magnet and Adjustment of Armature Position Indicator. 4551, p. 2

3 EB C. Adjustment The permanent magnet extension should be adjusted so that it just touches the two stop pins on the bottom of the armature with the nominal spacer, specified in Table 1, inserted between the main armature stop pin and the upper pole face. If necessary in order to obtain calibration values or contact openings, this spacer may be varied within the limits given in Table 1. With the armature released, both back stop pins should make contact with the permanent magnet extension face and neither should project over the edge of the permanent magnet. In this position, the air gap at the permanent magnet pole face should average inch parallel and must not be less than0.003 inch at any point. This is the physical air gap from plated pole face to plated armature. III. INDICATOR Adjustment of the armature position indicator after calibration should be made so that the bottom of the red painted surface is 1-13/16 inch from the main body of the relay frame. Viewed from the front of the relay with cover applied, the red indicator should be in full view with the armature in the de-energized position, and should be hidden with the armature in the energized position. Refer to Figure l for illustration concerning this adjustment. IV. CONT ACT ADJUSTMENT A. General The fingers supporting the contact springs should be straight and approxi - mately at right angles to the relay base. All adjustments of contacts should be made by bending the brass finger with a bending tool (Ml02225) applied between the rivets on the heel springs or near the bakelite contact block on the front and back springs. 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 support fingers should be adjusted sideways by using the alignment tool (M for heels and M for fronts and backs) so that the contact tips on all three members are approximately centered. 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 dressed, nothing coarser than a #6 pillar file should 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 SM , p. 3

4 TAl3LE l ADJUSTING AND TESTING TAl3ULATION FOR STANDARD PN-1501! RELAYS Adjust using Nominal values for Test Number 1-4 for all relays. If the hold-down force is too strong use maximum values. If the hold-down force is too weak use minimum values. For other Magnet adjustments refer to Sec. VIII. Test No A Relays with Original Design Heels Relays with I3ifurated Ileels Description Nominal Minimum Maximum Nominal Minimum Maximum Remarks Permanent Magnet Assembly 0.117" " 0.130" " 0.117" 0.130" Main Stop-Pin Space for Adjustment. Back Stop Pins Touching ~ Front Contact Adjustment 0.046" " Main Stop-Pin Space. Cont act Just Ope 11. Front Contact Adjustment 0.043" " Main Stop-Pin Space. Contact Must Close. -~--- Back Contacl Adjustment 0.031" 0.027" 0.031" 0.031" 0.027" 0.031" Back Stop-Pin Space. Contact Just Open I3ack Contact Compression Test 0.028" 0.024" 0.028" 0.028" 0.024" 0.028" Space between permanent magnet and Armuture lower Stop-Pins. Contacts Must Close ~ a-front Contact Openings " " ---- With Back Contacts Just Closed. b-front Contact Openings " " ---- Armature Released Agarnst Pe rmu11ent l\:lag11et c-front & Back Contact Openings " " ---- With Operating Arms Removed. Polarity Test Charge Charge Positive lead on upper left mounting base receptacle Value Value (viewed from front) for pick-up. With leads reversed, 'armature must stay clown. Reverse sever:11 times. Drop-Away Table Table After Charge. To Close Back Contacts Drop-Away to Full l3ack ---- Table Table After Drop-Away. Reduct.: cur rent untl I Ar111atu1 e Contact Pressure rests on Permanent Ma1,'l1et Break-Away from ---- Table Table 2 Of Actual Pick-Up for Break-Away from the Permanent Magnet Permanent Mai:,'11et Pick-Up Without Cover Table Table 2 Mark Actual Value on Left Side of Arn1i1turc. (To Close Front Contacts) With Cover % +5% % +5% Permissible Variation f Actual Pick -Up without Cover. Working (To Stop-Pin) Table Table 2 Hold-Down Torque.. _ Gms Gms ,Y---"-"' ---~-- Force on Bottom Contact Engaging 1'111 of Operating Arm to Pull Armature from l'ermanent l\1agnet After Charge. Final Electrical Inspection ~ Recheck Tests Nos. 6 to 11 with Cover Applied.

5 ~ B. Heel Contact Springs 3 2 {.100"... ox 020 ~-004' )C;r I APPROX J SAME PLANE Original Design Bifurcated Design Fig Heel Contact Springs 1. Original Design Before adjusting the heel springs it shouldbe determined that dimensions of O. 094" - O. 100 ti exist as shown in Figure 2 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 2 and that the free ends are aligned within 1/64 of an inch. 2. Bifurcated Design. Before adjusting these heel springs it should be determined that the dimensions exist as shown in Figure 2 and that the bifurcated parts have a slight trapped pressure against the main member. C. Adjusting the Front and Heel Contact Springs,. Using the Test No. 2 values per Table 1 at the rear of this specification, hold a gage of the proper value firmly at the main stop pin by energizing the relay, adjust the front contact springs so that light is just barely visible between the contact tips. A " thinner spacer should allow the contacts to close. Deenergize the relay and remove the gage. 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 so that there is from O. 005 ti to O.010" clearance between the front contacts and the 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. When replacing the operating arm make certain that the same side is to the front, as reversing the arm may change adjustments because of slight warpages and molding tolerances. On later production arms the word "Front" is molded on one side. 4551, p. 5

6 ffi UNION SWITCH & SIGNAL Reinsert the Test No. 2 gage used above, energize the relay and readjust the front contact springs as before. Check that the Test No. 2a value allows the contacts to close. D. Adjusting the Back Contact Springs Using the test No. 3 values hold a gauge of the proper value firmly at the back stop pins by energizing the relay in the reverse direction, adjust the back contact springs so that light is just barely visible between the contact tips. Check that test No. 4 allows the contacts to close. Again remove the operating arm and determine that the heel contacts have at least " opening at the front and back contacts as per test Sc. ~ If the operating arm is bumped while adjusting either the front or back contacts, de-energize the relay and position the operating arm by working the armature by hand a few times before proceeding. A check must be made that when the front contacts are just touching, the back contacts have at least U. 020" opening as per Test Sa. When the armature is in the fully released position, the front contacts must have at least U. USU" opening as per Test Sb. If any of the screws holding the contact springs into the contact block have been loosened or removed, when replacing them they must be tightened only with a torque screw driver set at 5 inch-pounds maximum. Further tightening may crack the bakelite contact block..after tightening these screws they should be sealed with Minnesota Mining Company's Cement #821 or Duca Household Cement, or equivalent allowing the cement to penetrate down alongside the contact fingers into the contact block. E. Replacing the Contact Block If the contact block is to be replaced by another, remove the old block, then use a small punch to remove the small dowel pins. Attach the new block with the four screws. Run a #42 drill ( Dia.) thru the dowel pin holes into the bakelite contact block for a total depth of 9/16" + 1/32-0. NOTE: Replacement contact blocks MUST be of the same general design. Carefully install the dowel pins, tapping in until they are flush with the aluminum surface. If it is necessary to install a used contact block from another relay, remove only one of the dowel pins from the aluminum frame. Carefully press the block on the remaining pin and fasten in place with the screws. One dowel pin will adequately hold the block in place. V. CALIBRATION After the relays have been inspected and adjusted, they should be calibrated to meet the values given in Table 2. Before calibrating, the relay should be energized at the "charge" value and no higher, the energization being pole changed several times allowing the current to build up to full value in each direction. 4551, p. 6

7 Relay Resis. Ohms TABLE 2 Calibration Values for Standard PN-150B Relays with 6 FB Contacts. Drop-Away Minimum With Full Back Charge Drop-Away Contact Compression Amps. Volts Amps. Volts Amps. Volts o Maximum Pick Up and Working (Full Stroke) Amps. Volts i:::. Ul Ul I-' "O. -..J c 2 i5 z i =i 0 :r 11!1 en c5 2 :,,. r- EE

8 A. Polarity (Table Test 6) The polarity should be checked as follows: With the negative power lead connected to the "+" or "+A" coil terminal, the positive power lead connected to the"-" or "-B" coil terminal, and the relay energized at the "charge" value, the armature should not pick up. With the polarity of energization reversed so that the positive power lead is connected to the"+" or "+A" coil terminal, the relay should pick up. The "+" or "+A" coil terminal is the left -hand coil terminal on the relay as viewed from the front of the relay. B. Drop-Away The relay should be given a charge of four times the pick-up value and the current then gradually reduced until the armature drops away, opening all front contacts. This value should not be less than the value specified for Minimum Drop-Away in Table 2. The current should be further reduced gradually and a check made that the back contacts are fully compressed (armature resting on the permanent magnet extension) at not less than the value specified for Drop-Away With Full Back Contact Compression in Table 2. C. Pick-Up Immediately after the drop-away value has been measured, the current should be reduced to zero, the circuit opened for one second, then the current again applied in the same direction, gradually increasing it until the armature moves away from the permanent magnet with a very definite sudden motion. This value should not be more than 95% of the actual pick-up value measured on the tested 6 contact relay. The current should be further increased until the armature picks up to close the front contacts. This value should not be more than that specified for Maximum Pick-Up in Table 2. D. Working This value should be obtained immediately after pick-up by further increas - ing the current until the armature completes its motion and closes against the pole piece. The working value should not be greater than the maximum value specified in Table 2. VI. SERVICE TESTS During any maintenance, clean the surface between the armature and the pole faces, especially the core pin area, using a lint free cloth and alcohol. It is recommended that relays in service be readjusted when one or more of the following conditions occur, using as reference the calibration values for new relays given in Table 2. A. Drop-Awayvalue of a trackrelay falls below85% of the newrelay value. B. Drop-Away value of a line relay falls below 67% of the new relay value. 4551, p. 8

9 ffi C. Drop-Away With Full Back Contact Compression (armature resting against permanent magnet) value falls below 33% of the new relay value. D. Pick-Up value increases to more than 110% of the new relay value. VII. CHECK OF CONTACT OPENINGS A. With the operating arm removed from the heel springs, all contacts should have an opening of at least that given in Table l for Test No. Sc. B. With the armature against the permanent magnet, there must be a front contact opening of at least that specified in Table l for Test No. Sb. C. With the back contacts just closed, there should be a front contact opening of at least that given in Table l for Test No. Sa. VIII. PERMANENT MAGNET HOLD-DOWN FORCE With the relay in the normal upright position and de-energized, a force measured with gage Nl05440 of at least 190 grams applied on the end of the bottom horizontal contact engaging pin of the operating arm should be required to cause the armature to move away from the permanent magnet. This check should be made before and after the relay has been calibrated and after energizing with the charge value using normal polarity of energization. Because of the allowable variation in the stiffness of the material from which the contact springs are made the hold down force may vary between relays that have the same strength magnets. For this reason then, on relays that have 275 grams or more hold-down force (using nominal spacers) replace one of the phosphor bronze screws (shiny nickel plating) that holds the magnet assembly to the pole piece with a tin plated steel screw (dull) ] which will shunt some of the magnetic flux. Bending the adjustable shunt away from the magnet slightly will raise the hold-down force if necessary. (See Fig. 1). IX. CONT ACT RESISTANCE Resistance of fr~nt contacts should be measured with the relay energized and the armature agamst the stop pin, that of back contacts with the armature in the de-energized position. Cleaned contact resistances l h f 1 must not exceed the va ues given m t e o lowing table. Type of Contacts Silver to Silver- Impregnated Carbon Silver to Silver Ohms Front Contact 0.09 Ohms Back Contact , p. 9

10 X. RELAY INDEXING The following data defines the indexing that has been established for relays covered by this specification: 1. The index code always consists of four figures (such as 0001, 0002, or 0101) and is used for both the relay and the indexing plate on the mounting base. 2. The index code for each relay can be determined from the relay part number and its suffix which is marked on the name plate attached to the front of the relay. The first two digits of the index code are the last two digits of the part number, and the second two digits of the index code are the last two digits of the suffix. This index number thus obtained should agree with the placement of the indexing pins in the numbered vertical rows on the back of the relay starting with the top pin and reading down. 3. The index code for each mounting base is determined by the placement of the holes in the numbered vertical rows of the large white nylon indexing plate which is affixed to the front of the mounting base. This indexing plate should not be removed from the mounting base unless it is damaged or the indexing is to be purposely changed to accommodate a relay of a different piece number. Discard the indexing plate which comes in a bag tied to the handle of all new relays unless it is needed for replacement of a damaged indexing plate or for application to a new mounting base. Never drill new holes in an existing indexing plate for then it would accommodate two or more relays of different part numbers. The same applies to the positions of the indexing pins in the back of the relay unless it is being converted to another part number , p. 10

11 ffi RELAY PART NO. N N N N N N PARTS LIST PN-150B BIASED DC LINE RELAYS WITH 6F-B CONTACTS COIL RESISTANCE OHMS REFERENCE FIGURE 3 RELAY REFERENCE A B c D E F Detail Item Part No. Description Relay Ref. 1 M H J M J M N M J N J J ! J J M U J J I M J J N Frame Latch Rod Speed Nut Latch Dowel Pin Spring Armature Complete Washer Screw #6-32 x 7/16 Fil. Stl. (T.P.C.S.) Contact Block Complete (Note "A") Screw #8-32 x 7/8 Rd. Stl. i:1ach. (T.Pl.) Operating Armature Indicator Washer #6 Arc. Screw #6-32 x 1/4 Hex. Stl. (T.P.C.S.) Permanent Ilagnet Assembly Complete Strap Washer, #8 Tension T.P. Screw #8-32 x l" Tin Pl. c.s. (Note B) Screw #8-32 x l" Bronze (NOTE Handle Lock Washer, #10 Int. Tooth (Ph. Bz. N.Pl.) Screw #10-32 x 3/8" Rd. Hd. Brass N.Pl. Coil 400 Ohm B) A 4551, p. 11

12 ... N Figure 3. PN-lSOB Main Assembly f( ~::: ::.-:: _..;_-.:..:: ::.1---r::J,1 i 11 I II I 1:! I : H r - ---,,--l n ' , ~ _J c z 0 z ' :::; 0 J: ~ {II c;i z )> r ' I ----~..,- ---i.... i,.~ - -~ -' I

13 ffi ' Detail Item PN-150B BIASED DC LINE RELAYS WITH 6F-B CONTACTS CONTINUED Relay Part No. Description Ref. N Coil 800 Ohm B N Coil 1300 Ohm c N Coil 100 Ohm D N Coil 240 Ohm E N Coil 25 Ohm F J Screw, 1/4-20 x 3/4 Hex. Cap. Stl. (T.P.C.S.) J J J J J J Screw, #4-40 x 3/16 Rd. Stl. F (T.P.C.S.) Name Plate Indexing Pin Gasket Cover Screw #6-32 x 3/8 Rd. Stl. (T.P.C.S.) Washer Screw Seal Wire Seal H M A J Calibration Tag N Parts Bag (See Note C) 0001 N Parts Bag (See Note C) 0002 N Parts Bag (See Note C) 0003 N Parts Bag (See Note C) 0004 N Parts Bag (See Note C) 0005 N Parts Bag (See Note C) 0006 M Operating Arm Spring A B c D E F NOTE "A" Individual relay contacts are no longer available. If contact replacements are necessary, a molded block contact assembly -- containing a complete set of new contacts -- should be installed. The old style, "screw and wedge" contacts, v1hich are still in good condition, may be retained as future replacements in relays still using such contacts. (Continued on next page). 4551, p. 13

14 ffi UNION SWITCH & SIGNAL NOTE "A" CONTINUED When reordering contact blocks, be sure to include the "-0001" suffix with Part Number. This assures proper processing of contacts for optimum performance in these relays. NOTE "B" Any combination of the Bronze or Tin Plated steel screws may be used as required to achieve proper hold down torque during calibration. NOTE "C" Parts bag is shipped with each new relay and is tied to the relay handle. The parts bag contains: (1) Instruction Tag, (1) Nomenclature Tag, (1) Indexing Plate, (2) #4-40 x 3/16" Rd. Hd. Stl. (Tin Pl.) screws (2) #6-32 x 1-1/4" Fil. Hd. screws. 4551, 1? 14

15 ffi PARTS LIST FOR MOUNTING BASE FOR PN-lSOB RELAYS Reference Figure 4 (USED ON RELAY PIECE NUMBER) N through N Detail Item Part No. N N J J J I J Part Description Haunting Base Complete (Note "D") Mounting Base Only Contact Receptacle Solderless #10 to #12 ivire Contact Receptacle Solderless #14 to #16 Wire Contact Receptacle Solderless #18 to #20 Wire Ser. #6-32 x 5/8" Fil. Hd. Stl. (Tin Pl.) Adhesive Seal Ser. #4-40 x 3/16" Rd. Hd. Stl. (Tin Pl.) Meter Test Plug Insulated test plug used for opening any coil or contact circuit & for removing receptacle springs. *Ser. 1/4" 20 x 1-1/4" Rd. Hd. Stl. (Tin P 1.) *Washer 1/4" Stl. (Tin Pl.) *Lockwasher 1/4" Stl. (Tin Pl.) *Nut Hx. 1/4" -20 Stl. (Tin Pl.) * NOTE: These Items are for attaching mounting base to rack and are contained in the muslin bag shipped with the "Mounting Base Complete" part number. 4551, I? 15

16 .. 'O. Figure 4. Mounting Base for PN-150B Relays ~ Yb 6'11 tiituff j! 0 _ Aftfll'LY AeOYI 1t[CC.. TACU s.,11,ng I J c z '5 z ~ ::::; 0 J: IP en Cl z )> r " 17 ' ' ~~,'-,0~ ~ 18 ~ v~ (6) 1 ~ ' '.'\ :'\' ~) \. \ ' '', D = " ' ~ J.,.~ -..,I, ""' I', I' ',o ',II...,.. V I ',t I 0 0--, (di a ijjl ' a g w ' g g ij;b g g ~ a g ID ', ggw -- '\, ' 0 0 ',/,' ~ \ <p" 111,f-,, n n 7" 2il \1 1-J\OUt-jT\~Ci ~~t.. Fe~ Pt--.! INDEXING PLATE AND MOUNTING SCREWS FURNISHED WITH RELAY CONTACT SPRINGS ON RELAY rrrrrrrrjr (' ( (' (' (' ( ( ( (',( ' ' ' r'r~rr r r r r ~ rrc rcrcrc = = = \ = = = = = = = = =

17 ffi NOTE "D" When "Ilounting Base Complete" is ordered a muslin bag of parts 4-1/8" x 5-1/2" is included in the inner carton with mounting base and instruction prints. Bag contains:.. (2) Tags (4) #4-40 scrs. x 3/16" Rd. Hd. Stl. T.P. (2) Lockwashers 1/4" Steel (Tin Plated) (2) Flatwashers 1/4" Hx. Hd. Stl. (Tin Plated) (2) Nuts 1/4" Hx. Hd. Stl. T.P. (2) Screws 1/4" - 20 x 1-1/4" Rd. Hd. Stl. and (Req'd. Quant.) Contact Receptacles, Solderless J for #14 to #16 wire. If other i:. 1ire size is used request the proper Part Number as shown in Item 4 when ordering base complete. (i.e. N except using Contact Receptacles, Solderless J680181) 4551, p. 17