PN-250BE D.C. HIGH EFFICIENCY BIASED PLUG-IN RELAY. (li to 007) TABLE OF CONTENTS ARMATURE AIR GAP ADJUSTMENT CHECK OF CONTACT OPENINGS

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1 SERVICE MANUAL 4563 PN-250BE D.C. HIGH EFFICIENCY BIASED PLUG-IN RELAY (li to 007) TABLE OF CONTENTS Section I II III IV v VI VII VIII ARMATURE AIR GAP ADJUSTMENT PERMANENT MAGNET INDICATOR CONTACT ADJUSTMENT CALIBRATION PROCEDURES SERVICE TESTS CHECK OF CONTACT OPENINGS PERMANENT MAGNET HOLD-DOWN FORCE Page IX x XI XII May, 1983 C CONTACT RESISTANCE RELAY INDEXING MAINTENANCE PARTS LISTING UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC. Swissvale, PA 15218

2 This service manual povers the necessary information for the adjustment, calibration and repair of PN-250BE high efficiency biased plug-in relays N through N This Service Manual also includes supplementary information for: SM4563-A PN-250BE Relay for Time Code Control System (N ) SM4563-B PN-258BSR Slow Pick-Up, Slow Drop-Away Relay SM4563-C PN-258B Slow Pick-Up, Ordinary Release Relay SM4563-D PN-259BSR Slow Drop-Away Relay SM4563-E PN-250B D.C. Biased Neutral Plug-In Relay SM4563F PN258BC Biased Decoding Relay SM4563-G PN-250P Power Switching D.C. Relay SM4563-H PN-259SRA Slow Drop Away Relay.. Ascertain from Figure 2 whether the relay has old or new type heel springs. This will determine which adjustment spacers should be used throughout this specification. NOTE: PN-250BE Relays, Part Numbers N through N are no longer manufactured. If replacement is necessary order a corresponding N through 707 (with coil test facility) or N through 907 (without test facility). 4563, p. 2

3 WABCD SECTION I ARMATURE AIR GAP ADJUSTMENT On relays with 6F-6B contacts, the armature is set at the factory to a parallel air gap of inch. Main and rear stop pins determine this air gap... Safety stop pins must not touch the pole faces SECTION 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 Figure 1 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 4563, p. 3

4 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. MAGNETIC SHUNT ADJUSTABLE SHUNT MAGNET EXTENSION PHOSPHOR BRONZE OR TEEL SCREW AS REQUIRED Figure 1. Assembly of Permanent Magnet and Adjustment of Armature Position Indicator C ADJUSTMENT The permanent magnet exension 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 in the released position and reverse energy applied to the relay coils both back stop pins should make contact with the permanent magnet extension face and neither should project over the edge of the permanent magnet. Both nylon stop pins should also make contact with the rear pole piece at this time. In this position, the air gap at the permanent magnet pole face should average inch parallel and must not be less than inch at any point. This is the physical air gap from plated pole face to plated armature. 4563, p. 4

5 WABCO SECTION III INDICATOR Adjustment of the armature position indicator after calibration should be made so that the bottom of the red painted surface is 1-13/32 inches 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 1 for illustration concerning this adjustment. SECTION IV CONTACT ADJUSTMENT A. GENERAL The fingers supporting the contact springs should be straight and approximately at right angles to the relay base. vertical adjustments of contacts should be made by bending the brass finger with bending tools (Pcs. Ml02228, M301972, and M A2586-Sh. 27) 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 by using the alignment tool (Pc. M for heels and M for fronts and backs) so that the contact tips make with overlap approximately the same on both sides. Contact surfaces should not be disturbed unless there is evidence of servere pitting from excessive loading or an accidental short through the contacts. In case contacts must be redressed, 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, the contacts should be cleaned per Service Manual , p. 5

6 WABCD The contact resistance should then be checked, before and after the relay covers are applied, to values lower than service specification limits. It is desirable to obtain as low a value as possible consistent with the characteristics of the type of contact being cleaned. Silver impregnated carbon contacts which will not meet the required values may be sanded with #4/0 Metallographic emery paper and again cleaned and dried per Service Manual Occasionally it is necessary to sand and reclean the carbon a second time before the lower limits are met. B HEEL CONTACT SPRINGS 2 2 Original Design.100" -e {.100'' { APP,04' APPROX Ot6" New Bifurcated Design JI SAME PLANE Figure 2. Heel Contact Springs 1. Original Design Before adjusting the heel springs it should be determined that dimensions of 0.094" " exists 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. New 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. 4563, p. 6

7 WABCD C ADUSTING THE FRONT AND HEEL CONTACT SPRINGS Using the #2 test spacer from Table #1 at the rear of this manual, held 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 O.003'' thinner spacer should allow the contacts to close. De-energize the relay and remove the spacer. Remove the operating arm and hold it clear from all heel springs. Adjust the heel spring members so that there is from 0.005" to 0.010" 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 be careful to keep the same face forward. Reversing the arm may change adjustments due to slight warpages and molding tolerances. New arms have the word "Front" molded on one side. Replace the #2 test spacer, energize the relay and readjust the front contact springs as before. Check that the #2A spacer allows the contacts to close. D. ADJUSTING THE BACK CONTACT SPRINGS Using the #3 test spacer held 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 the #4 test spacer allows the contacts to close. Again remove the operating arm and determine that the heel contacts have at least 0.005" opening at the front and back contacts. 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 0.020" opening. When the armature is in the fully released position, the front contacts must have at least 0.050" opening. When replacing or tightening any of the screws holding the contact springs into the contact block they must be tightened with a torque screw driver set at 5 inch-pounds maximum, tightening the upper row first. Further tightening may crack the bakelite contact block. After tightening these screws they should be sealed with Minnesota Mining Company's 4563, p. 7

8 WABCD 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 maintaining.004" to.008" free vertical travel of the rear end of the armature. Run a #42 drill (.0935 Dia.) thru the dowel pin holes into the bakelite contact block for a total depth of 9 /16 II + 1/32-0 Carefully install the dowel pins, tapping in until they are flush with the aluminum surface. SECTION V CALIBRATION PROCEDURES 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. A. THE POLARITY The Polarity should be check as follows: With the negative power lead connected to the "+A" coil terminal, the positive power lead connected to the "-B" coil terminal and with applicable jumpers per Figure 3 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 "+A" coil terminal, the relay should pick-up. The "+A" coil terminal is the upper lefthand coil terminal on the relay as viewed from the front of the relay. 4563, p. 8

9 WABCCI + -A +A + -B +B SERIES CONNECTED MULTIPLE CONNECTED Figue 3 External Connections To Mounting Base Receptacle Springs B. DROP-AWAY The relay should be given a charge as specified in Table 2 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 Orop-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-point 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 increasing the current until the armature completes 456 3, p. 9

10 WABCD its motion and closes against the stop pin. The working value should not be greater than the maximum value specified in Tabl 2. SECTION VI SERVICE TESTS It is reconunended 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-Away value of a track relay falls below 85% of the new relay value. B. Drop-Away value of a line relay falls below 67% of the new relay value. 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. SECTION 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 1 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 1 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 1 for Test No. SA. 4563, p. 10

11 WAEICCJ 'V" SECTION VIII PERMANENT MAGNET HOLD-DOWN FORCE With the relay in the normal upright position and de-energized, a force measured with gage Pc A2586-Sh. 29 of at least the value given in test #12 applied in the center 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 heel 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 excessive hold-down force (using nominal spacers) replace one of the phosphor bronze screws (shiny nickel plating) that nolds the magnet assembly to the pole piece with a dull tin plated steel screw J 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). SECTION IX CONTACT RESISTANCE Resistance of front contacts should be measured with the relay enr,g.i.zed and the armature against the main stop pin, that of back contacts with the armature in the de-energized position. Cleaned contact resistances must not exceed the values given in the following table. Type of Contacts Silver to Silver Impregnated Carbon Silver to Silver Ohms Front Contact 0.09 Ohms Back Contact , p. 11

12 WABCC SECTION X RELAY INDEXING The following data defines the indexing that has been established for relays covered by this manual. 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's piece 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 piece number, and the second two digits of the index code are the last two digits of the piece number suffix. This index number thus obtained should agree with the placement of the indexing pins in the numbered horizontal rows on the back of the relay starting with. the pin in row A, then B, C, and D. 3. The index code for each mounting base should agree with that of the relay and is determined by the placement of the holes in the rows of the large white nylon indexing plate contained in the bag tied to the relay handle and which should be 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 plate for then it would accommodate two or more relays of different piece numbers. The same applies to the positions of the indexing pins in the back of the relay unless it is being converted to another piece number. 4563, p. 12

13 Test No A TABLE 1 ADJUSTING AND TESTING TABULATION FOR STANDARD PN-250BE RELAYS Adjust using nominal spacers for test number 1-4 for all relays. If the hold-down force is too strong use maximum spacers. If the hold-down force is too weak use minimum spacers. For other Magnet adjustments refer to Sec. VIII. Relays with old style Heels Relays with new style Heels (See sheet 6) (See sheet,) Description Nominal Minimum Maximum Nominal Minimum Maximum Remarks Permanent Magnet Assembly 0.108" " 0.130" 0.138" Main Stop-Pin Spacer for Adjustment. Back Stop Pins Touching. Front Contact Adjustment 0.040" " 0.031" 0.055" Main Stop-Pin Spacer. Contact Just Open. Front Contact Adjustment 0,037" - - o. 04 7" o. 0 2.i" 0.052" Main Stop-Pin Spacer. Contact Must Close. Back Contact Adjustment 0.048" 0.044" " 0.042'' 0.050" Back Stop-Pin Spacer. Contact Just Open. Back Contact Compression Test 0.045" 0.041" " 0.039" 0.047" Spacer between permanent magnet and Armature lower Stop-Pins. Contacts Must Close. a-front Contact Openings " " - With Back Contacts Just Closed. b-front Contact Openings " " - Armature Released Against Perm. Magnet. c-front & Back Contact Openings " " - With Operating Arms Removed. Polarity Test Charge - - Charge - - Mounting base wired per applicable diagram Value Value of Fig. 3 for Pick-Up. With Reversal, Armature must stay down. Rev. Several Times. Drop-Away - Table Table 2 - After Charge. To Close Back Contacts. Drop-Away to Full Back - Table Table 2 - After Drop-Away. Reduce current until Contact Pressure Armature rests on Permanent Magnet. Break-Away from 6 Pt % % Of Actual Pick-Up for Break-Away from the Permanent Maet Permanent Magnet. Pick-Up Without - - Table 2 -. Table 2 Mark Actual Value on Left Side of Armature. cover (To Close Front With cover - 5% +5% - -5% +5% Permissible Variation from Actual Pick-Up contacts) without Cover. Working (To Stop-Pin) - - Table 2. - Table 2 Hold-Down Torque 6 Pt Oms Oms.. Force on center of Bottom Contact Engaging pin of Operating Arm to Pull Armature from Permanent Magnet After Charge. Final Electrical Inspection Recheck Tests Nos. 6 to 11 with Cover Applied. ii:.. Ul ' w.. I'd... w i

14 WABCEJ TABLE 2 Relay Resis, Ohms Connected per Fig, 3 Calibration Values for Standard PN-2508B Relays with 6F-6B L V Contacts Minimum Charge Drop-Away Amps, Volts Amps. Volts Drop-Away With Pull Back Contact Compression Amps. Volts Maximum Pick Up and Working (Full Stroke) Amps. Volts l Series Multiple Series Multiple Series Multiple Series Multiple Series Multiple Series Multiple , l , , , SECTION XI MAINTENANCE 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 other contamination of parts, loose parts inside of cover, broken seal, and cracked or broken cover. 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. 4563, p. 14

15 SECTION XII PARTS LIST FOR PN250BE RELAYS WABCD Relay Part No. N N N N N N Reference (see column) A B c D E F ITEM PART NUMBER DESCRIPTION REF a 19b 19c M M J M M J M M M N J J N M M M M M N N N N J M J M R J J N M M M M M M J J Frame Rod, Latch Button, Latch Nut Latch Pin Dowel Spring Plate, Armature Mounting Spacer Spring, Armature Hold-Up Screw #6-32x7/16" Hex. Stl. T.Pl. c.s. Screw #6-32xl/4" Hex. Stl. T.Pl. C.S. Armature Complete Spring, Operating Arm Lock, Bolt Washer Spring Horizontal Lock, Bolt Block, Con.tact (Complete) Contact Spring Contact Spring Contact Spring Screw #8-32x7/8" Rd. Hd. Stl. T.Pl..Washer Screw 6-32x3/8" Flat Stl. T.Pl. C.s. Arm, Operating Pole Piece and Core Assembly Screw #8-32x3/4" NYLOCK Fil. Screw #8-32x5/8" Flat Stl. T.Pl. C.S. Magnet Assembly (Complete & Magnetized) Strap Lock, Bolt Screw (See Note "A") Indicator Lock, Bolt Screw Block, Contact Screw #8-32x3/8" Flat Stl. T.Pl. Seal Rubber. 4563, p.15

16 WRBCD PARTS LIST FOR PN250BE RELAYS (cont'd) ITEM PART NUMBER Nl84912 Nl44439 Nl89122 Nl Nl45969 N M M M J J M J M M J J A J J J N N N N N N Ml Ml68826 J M J N J J J DESCRIPTION Coil (Resistance-Series/Mult) 2/0.5 ohm Coil 4/1 ohm Coil 55/13.75 ohm Coil 175/43.75 ohm Coil 1000/250 ohm Coil 2000/500 ohm Lock Coil Back Strap Screw Pin, Indexing Gasket Spacer, Arm (use as required) Cover Screw Handle Washer, Lock #10 Int. Tooth Ph. Bz. N.Pl Screw #10-32x3/8" Rd. Hd. Br. Ni. Pl. Tag, Calibration Wire, Seal Seal Plate Name Screw #4-40x3/16" Rd. Stl. (F) T. Pl. C.S. Bag of Parts Bag of Parts Bag of Parts Bag of Parts Bag of Parts Bag of Parts Washer Washer (Incl. (Incl. (Incl. (Incl. (Incl. (Incl. Indexing Plate) Indexing Plate) Indexing Plate) Indexing Plate) Indexing Plate) Indexing Plate) Nut #6-32 Elastic Stop Plugs Screw #8-32x7/16" Fil. Stl. T.P. Cover & Testing Device Screw #6-32 x 1/4" Fil. Stl. TP. Washer #6 Arc Washer, Tension T.P.C. REF. A B c D E F A B c D E F Note "A": Any combination of the Bronze (M327179) or Steel ( J463078) screws may be used as required to achieve proper hold down torque during calibration. 4563, p. 16

17 GENERAL ASSEMBLY DWG. FOR PN 250BE RELAY WITH PIECE NO.N THRU 006 lu====-- ' I MUI,...gJ ,,e ls 01r.,,,.,.,.,,... c:a r.:::1 c:::s c:2 -ci""lo = c::::1 c:, c:::1 c::11jo ti::. U1 O'\ w... 'O I-' " Figure 4. PN-250BE Main Assembly i

18 .i::. Ul O'\ w... "Cl I-' CX) (oi i i i i i 1 1 D I CONTACT CONTACT SECTION ROW BLOCK N A A A A A A SECTION-"A" SECTION-"A SECTION-"88 11 SECTION-"cc'' PERMANENT MAGNET it ==, "A" ill' 1' Figure 5. PN250BE Detail Parts ARMATURE

19 WABCD MOUNTING BASE PARTS LIST FOR PN-250BE RELAYS ITEM PART# PART DESCRIPTION 1 N Mounting Base Complete {Note B) 2 N Mounting Base Only (without receptacle springs) 3 J Tag 4 J J J M J NOTE "B" Bag Contains: (Req'd Contact Receptacle Solderless #10 to #12 Wire Contact Receptacle Solderless #14 to #16 Wire Contact Receptacle Solderless #18 to #20 Wire Meter Test Plug Insulated Test Plug {For Opening any coil or contact circuit and for removig receptacle springs) When Mounting Base complete is ordered a muslin bag of parts 4-1/8" x 5-1/2" is included in the inner carton with the mounting base and instruction prints. (2) Tags (4) (4) (4) (4) (4) * (4) and Quantity) #4-40 x 3/16" Rd. Hd. Screws 1/4" steel plate washers 1/4" -20 x 1-1/4" Rd. Hd. Stl. Screws Washers 1/4" steel lockwashers 1/ Steel Hex Nuts Contact receptacles {solderless) J for #14 to #16 wire. If other wire 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). Asterisk (*) Items are for attaching mounting base to the rack. 4563, p. 19

20 WABCD - r-- cc - sq (l,j Il Il TI II 11 II II IT Il U D $ nnarrnn 10 Il II 11 Il 1I II III IT II Il II II.n Il II II IT II 9 ITIIIJl1IIII IIITilIJDil {;' I.O.. µ:.; , p. 20

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22 UNION SWITCH & SIGNAL DIVISION HEADQUARTERS American Standard Inc. Swissvale, PA (412) PHILADELPHIA OFFICE JACKSONVILLE OFFICE NEW YORK OFFICE EASTERN OFFICES WESTERN OFFICES. 2 Penn Center Plaza (215) ST. PAUL 402 McColl Bldg. Room 1630.OFFICE 5th & Jackson Philadelphia, PA St. Paul, MN P.O. Box 8609 (904) SAN 903 Sneath Lane Jacksonville, FL FRANCISCO Suite 2300 OFFICE San Bruno, CA W. 40th. St. (212) Room ST. LOUIS 500 Northwest Plaza f>!ew York. NY OFFICE Suite 820 St. Ann, MO (612) (415) Or 6789 (314) CANADIAN OFFICE MONTREAL OFFICE 1155 Dorchester Blvd.,W.Suite 1003 Mont.,PO Can.,H3B 2J2 (514) REGIONAL OFFICES ATLANTA ROANOKE OFFICE HUNTINGTON OFFICE CHICAGO OFFICE OMAHA OFFFICE (404) (703) (304) (312) (402) MAIL ALL ORDERS TO: ORDER ENTRY DEPARTMENT UNION SWITCH & SIGNAL DIVISION AMERICAN ST AND ARD INC. SWISSVALE PA 15218