Section

I

II

III

IV

v

VI

VII

VIII

IX

x

XI

XII

'

November, 1980 A-80-1.00-2346-2

..... ,,. ... t&~ ...

WABCCJ ~·

SERVICE MAN.UAL 4551-F~.

PN-150P PLUG-IN POWER TRANSFER RELAYS (4-POINT)

PC. NO. SERIES N322508-702, N322508-703

CONTENTS

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

1

1

1

1

2

6

8

8

8

10

10

11

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD .. INC .

C'°. • ~=-· -· .. -I' - I""'\ A A,:-,...,. .. I""\

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Section

I

II

III

IV

v

VI

VII

VIII

IX

x

XI

XII

'

November, 1980 A-80-100-2346-2

WABCD ~

SERVICE MANUAL 4551-f

PN-lSOP PLUG-IN POWER TRANSFER RELAYS (4-POINT)

· ·· · - ·- .PC: · NO.·· "'SERIES N322508-702, N322508-703

CONTENTS

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

1

1

1

1

2

6

8 .. ·~ "'rl

8

8

10

10

11

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC.

C\, ••• !--··-1- F"'\A ,4r"" .. " . ~., ...

UNION SWITCH & SIGNAL W

I. GENERAL INFORMATION

·:> 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

4-Point

III. PERMANENT MAGNET

Air Gap

0.040 11

Refer to Service Manual SM4551, except use the following adjustment spacers:

4-Point Relay - Use a spacer 0.145 11 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

~ 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 N451151-0801 (Dwg. B451151-08). 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-4560.

5.2 Heel Contact Springs

3 2

Original Design New Design

Fig. l ••• Heel Contact Springs

5.2.1 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.

5.2.2 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

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

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

UNION SWITCH & SIGNAL ID

r- --, BATTERY .... I Ac I :I I I AC I ,fA.. • :, , )f,. ' •c+ " c- :,

XR I ( _______ ,,

OR l+A -A I X'I'PR

==-2H

BX OR B

TO LIGHTS NX NX OR N

N

Figure 2, Typical Circuit Application of PN-lSOP Power Transfer Relay in Highway Crossing Scheme Utilizing Special Stick Circuit. ·

Sl-14551-Fl, p. 5

UNION SWITCH & SIGNAL

':::,,-,"

INTERNAL ,--------1 RECTIFIERi---iH--1--...J. )I '11t. I ~ >----· 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 68 58 48

NOTE! CONTACTS SHOWN ARE FOR 4-POINT RELAY

2F-2H STICK CONTACT

Figure· 3 - Wiring of Contact Block

-- --.+--·-------~--..::r,,-..,,..-i~ t •• - - - -=--------~ - .. - - - .;.;;. ;;;:;;.-. ..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

EXTERNAL JUMPERS

r-;:;--A

•-8

c-C+

AC • 6F •

• 2'

la AC • SF •

• IF • IH • II • 4F • I

6H SH • • 61 51 ___ ;_J

REAR OF MOUNTING SASE

UNION SWITCH & SIGNAL Q)

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.

6-1. 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

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.

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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

Test No.

1.

. 2,a

b

3.

4.

5.a

b

c

6,

7.

8,

9.

10.

''t.S 11.

TABLE l -- ADJUSTMENT AND CALIBRATION SUMMARY FOR PN-150P POWER TRANSFER RELAYS

4 Point Relay Stick 2F Remarks

Nominal Min. Max. Cont. 2H

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" .035 • 030 Contact Just Open •

Front Contact Main Stop-Pin Spacer. Adjustment 0.048" 0.043" 0.053" .030 .025 Contact Must Close.

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 --- 0.020" --- With Back Contacts Just

Adjustment.

Closed.

-Front Contact Armature Released Against Openings --- 0.050" --- Permanent Magnet.

-Front & Back With Operating Arms Contact Openings --- 0.005" --- Removed.

Droo-Awav --- Table --- After Charge. To Close Back Contacts. -Drop-Away to Full After Drop-Away, Reduce Current Back Contact Until Armature Rests on Permanent Pressure --- Table --- Maqnet

Break-Away From Of Actual Pick-Up For Break-Away Permanent Magnet --- --- 95% From the Permanent Magnet.

Pick-Up and Mark Actual Value on Left Side Working --- --- Table of Armature

Force on Bottom Contact Engaging Pin Hold-Down of Operating Arm to Pull Armature Torque 250 gms from Permanent Magnet After Charge.

Final Electrical Recheck Tests No. 6 and 9 With Inspection Cover Aoolied.

c z 0 z i ~ :c

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5 ~ ,..

UNION SWITCH & SIGNAL

X. CONTACT RESISTANCE

Refer to Service Manual SM4551, except use the following contact resistance values:

Type of Contacts

Silver-to-Silver­impregnated carbon

10.1 Current Rating

Ohms (Front and Back Contacts}

o.os

HD (Heavy Duty) contacts are rated 15 amperes maximum first range voltage (0 - 30 volts 4 AC Only.)

XI. RELAY INDEXING

Refer to Service Manual SM4551.

TABLE 3 ••• PN-ISOP (4.,Point) Calibration Values

Drop-Awa.y Full Back Maximum Relay

Volts (A-C.) Contact Pressure Pick Up and

Resistauce Charge Drop-Away Working

Ohms Volts (A-C.) MIN. MAX. Volts (A-C.) Volts (A-C.)

240 10 7.0 - 7.3 3.5 9.0

400 12 a. 4 - 8. 75. 4.2 10.8

SM4551-Fl, p. 10.

XII. PARTS LIST

Item No. Piece Number

1 .., "" 3 4 5 ~ 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25

27 28 29 30 31 32 33 34 35 36 37.

39

43 44 45

N438410-001 M388888 Ml96812 M263919 M321728 J48716 M321861 See Tabulation M291657 J52243 See Tabulation J522168 M373632 1-1321894-002 M438415 M437306-001 See Tabulation !-1321853 M262770 See·Tabulation M321821 J47710. J525577

See Tabulation l-1321746

J50016 J525024 See Tabul;:,,tion J487090 J47081 N438424 J525031 .M34 7631 M321747 A43013 J79351

053665 U52955

M:349785-001 J047713 See Tabulation

UNION SWITCH & SIGNAL

(Refer to Figure .6)

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.

Spring, Operating Arm Wash. #6 Shprf. Lk. Spacer, Magnet

SM4551-rl, p. 11

UNION SWITCH & SIGNAL

XII· PARTS LIST CONTINUED (Refer to Figu:r::~ 6)

Item No.

46 47 48 49 50 51 52 53 54 55

Piece Humber

M451176-0401 J790257 M451574-0101 i14·51496-6201 M451446-1801 M451446-1701 M341634 J487087

. l-1-434609 J776595

SM4551-Fl, p. 12

Description

Counterweight Seal, Vent lilut, Lock

· Tag Spacer Plate, Adjustment Ser., ~6-32xl5/16 Hex. Cap Stl. Pin, Roll washer, Plate Block, Cover Fastening

.. /

..

:)

O~SCRIPTION OF KIND COIL €) CONTACTS AC RELAY OF

PC. NO. VOLTS STYLE RELAY OHMS 066001

lF L.V. ORDINARY UN322508-702 4F & 4B L.V. HD 10 PN-lSOP ACTING 240 UN333975

lF L.V. ORDINARY UN322508-703 4F & 4B L.V. an 12 PN-150P ACTING 400 UN321647

screw for Fastenin Permanent Hagnet Assy. to Pole ~ Piece (See Note J

J463078

@) Permanent

Hag net & Soacer 835028 I SH.

..t347526 I l

erma'len ··@ Magnet

Assembly

1274!? SH. M344418 151

Contact Block@

066001 be. N4J8420 16

Arma Lure Assembly

066001

N344118--001

© SH.

5

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~ &,,..,._)

AIR GAP SPEC (PARALLEL)

EU SEE SPEC.

SH. "A" "B"

39 6310 .036 .004 .036 39 .. 6310 .004

r '":l ! ' I j_

s~cr,oN ·c·c ·

UNION SWITCH & SIGNAL \JJ LOCATION OF PARTS BAG COMPL. !40UNTIUG BASE

INDEXIHG PINS STAHDARO

{FOR REF. ONLY) NAME PLATE WITH PROPER WITH SOLDERLESS ROW (INDEXING PLATE) INDEXING PLATE TYPE RECEPTACLES

A B c 0 06601 SH. 8225 SH. ru:;c.nnt ~R. -,,,,.. --.. / c::u_ Ui"!~::>J..'!~b-b"lUJ.. . 11438562 0 8 0 2 UM322078-0802 8 8451496-SH 64 UN3 "lnf;Rl -oRn? q 1 UM45.l.4~b-640.l. N438562 0 8 0 3 UM322078-0803 8 8451496-SH 64 UN"l"l06R1-080"l q 1

rr-~---~- -~-- ~ --1 1-i--- -- ----, r - -- - --:-~! i,1-- - -- - -,- -- -- - --1"- -- -J - .. , -1-'-- .. -.-------~.,. .. ----r--J---t ____ _

•; l I I •• I I I 11 I I --~--------------~---~~~ a-------j ~---~_; ___ ~

Gt

!' l ~.--------------- _____ 1

"4Ta"K"--Y S&AL \1'1,N ~ ova tt VU41' OM OUT 'ii"°' ol' owe-.

& 5".., 70 154 IJ$t!D /IIS "all)1J1'2.&D 1'0 oaT .... 11,I $TIZOKC Pt!lff Sf"Et!- IU-i.!,/0.

Figure 6, PN-lSOP Plug-In Power Transfer Relay _SM4551-Fl, p. 13/14

• :.- >

SERVICE MANUAL

ADDENDUM

PERIODIC MAINTENANCE

WABCO ~~

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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