SM 4596F - Ansaldo STS
Contents
1. NOTE A When mounting base complete is ordered a bag of parts is included in the inner carton with the mounting base and instruction prints Bag Contains Tags Item 6 Screws Item 7 and Items 8 9 10 and 12 which are used for attaching the mounting base to the rack Included Also are Required Quantity Receptacle contact springs solderless J680165 for 14 to 16 wire If other wire size is used request the proper part number as shown in Item 1 when ordering base complete i e N438562 except using receptacle contact springs solderless J680181 A 4 SM 4596F August 1986 Rev 0 N 77 Ansaldo STS A Finmec Company Appendix A Parts List N E Le N 2 o N Figure A 2 Old Style Mounting Base SM 4596F August 1986 Rev 0 A 5 Appendix A Parts List ER Ansaldo STS 4 8 Parts List for Improved Mounting Base for PN 150P Relays See Figure A 3 DESCRIPTION PART NUMBER Base Complete for Wayside Relays Note A N451376 0302 Base Only N451376 0301 Base Complete for Car Carrying Relays Note A N451376 0303 Base Mounting Molded J780055 Strike Relay J792848 Nut Speed Push On J480280 Receptacle Contact Spring M451142 2702 Screw 1 4 20 x 1 1 4 Rd J052667 Washer 1 4 Stl Lk Med J047775 Washer 1 4 Stl Plate J047501 Nut 1 4 20 UNC 2B Hwy J042. Each solderless receptacle contact spring should be inspected for physical damage and straightness before proceeding with installation The following is recommended when installing solderless receptacle contact springs a Receptacle contact springs must be inserted into the base with the lock side down See Figure 2 2 b Make certain that the lanced tab is slightly compressed when the receptacle contact spring is inserted along the top of the cavity The lanced tab could have been bent during handling and therefore would not provide the required contact pressure after the relay is inserted If the lanced tab does not touch pull it up slightly using fingers or a suitable tool c After insertion pull firmly on the wire to make certain the receptacle contact spring is locked in the receptacle 2 2 SM 4596F August 1986 Rev 0 SA 7a Ansaldo STS Installation INDEXING PINS SH pu S Majo oo O00000 090 E SEN 00000 Es oo Ch bd 2000 za z DS a oy a INDEX PLATE Y S Y 2 gt s Sc Ss Y C bs Ss S NEE Ees i E MOUNTING BASE Figure 2 1 Typical Plug In Relay and Mounting Base RECEPTACLE CONTACT SPRING RECEPTACLE CONTACT SPRING LANCED TAB LANCED TAB LOCK SIDE LOCK SIDE OLD MOUNTING BASE IMPROVED MOUNTING BASE Figure 2 2 Receptacle Spring Installed SM 4596F August 1986 Rev 0 2 3 I
3. 0 048 0 058 Main Stop Pin Spacer Contact Just Open Front Contact Adjustment 0 048 0 043 0 053 Main Stop Pin Spacer Contact Must Close Back Contact Adjustment 0 081 0 086 Main Stop Pin Spacer Contact Just Open Back Contact Adjustment 0 ose 0 091 Main Stop Pin Spacer Contact Just Close Front Contact Openings 0 020 With Back Contacts Just Closed Front Contact Openings 0 050 Armature Released Against Permanent Magnet Front and Back Contact Openings 0 005 With Operating Arms Removed Drop Away Table 4 2 After Charge To Close Back Contacts Drop Away To Full Back Contact Pressure Table 4 2 After Drop Away Reduce Current Until Armature Rests on Permanent Magnet Break Away from Permanent Magnet Of Actual Pick Up for Break Away from the Permanent Magnet Pick Up and Working Mark Actual Value on Left Side of Armature Hold Down Torque 250 Gms Force on Bottom Contact Engaging Pin of Operating Arm to Pull Armature from Permanent Magnet After Charge Final Electrical Inspection Recheck Tests No 6 and 9 with Cover Applied Table 4 2 PN 150P 4 Point Calibration Values Coil Resistance Ohms Normal Charge Volts AC Drop Away Volts AC Full Back Contact Pressure Min Max Drop Away Volts AC 10 7 0 7 3 3 5 12 8
4. Ansaldo STS 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 S M 4596F POWER TRANSFER VITAL RELAY PN 150P Second Generation ASTS USA Part Numbers THIS MANUAL SUPERSEDES SM 4596F DATED JULY 1984 Copyright 2013 SM 4596F Rev 0 Ansaldo STS USA Inc August 1986 77 Ansaldo STS Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it
5. attached to the contact springs NOTE When using the paper strip clean the back contacts first then the front contacts last Discard the paper strips when dirty 4 2 SM 4596F August 1986 Rev 0 Ansaldo STS Shop Maintenance SAFETY PINS STOP PIN Figure 4 1 Armature Stop Pin Location 4 2 2 1 Contacts That Are Severely Burned a Using a 600 grit emery paper strip folded with the grit side out so that both contacts can be burnished simultaneously stroke the contacts in the direction of contact wipe b Using the burnishing tool stroke the contacts several times in the direction of contact wipe c Place the paper strip between the open contacts then close the contacts and withdraw the paper strip d Repeat step c several times if necessary Using the Freon TF spray give the contacts a degreasing wash f Place the paper strip between the open contacts then close the contacts and withdraw the paper strip g Repeat step f several times if necessary 4 2 2 2 Contacts with Heavy Tarnish Slightly Rough or Pitted Perform the procedure in Subsection 4 2 2 1 Steps b to g 4 2 2 3 Contacts with Surface Film or Oxidation Not Pitted Perform the procedure in Subsection 4 2 2 1 Steps f and g 4 3 CHECK OUT PROCEDURE Performance Test Perform calibration in accordance with Section 4 6 4 4 REPAIRS AND REPLACEMENT Since the contacts are the only wearing
6. 4 4 SM 4596F Table of Contents List of Figures Typical Plug In Relay and Mounting Base sse 2 3 Receptacle Spring Installed ritenere eet do ee in bane dne GER GN oaa 2 3 Rectifier Installation Wiring Diagram iese ee ee AR AA Re nennen nene 2 5 Typical Circuit Application of PN 150P Power Transfer Relay in Highway Crossing Scheme Utilizing Special Stick Circuit ee ee ee eene enne 2 7 Wiring of Contact Block EE EE EE EO EE erede Eoo edebat e ne tut 2 8 Relay Base Before dT OR cc N N cias 3 2 Armature Stop Pin Location ice ortu nd ex noe GE ke ae XR GR KOR ER SR e ER aaa Ce ARA de 4 3 Assembly of Permanent Magnet iese ee ee ee AR ee AR Re AA ee rn ee ee rr cnn ee ee ee ee ee ee ee ee 4 6 Heel Contact Spring iese se ee ee ee AR Ee AR ee AR rra 4 7 PN 150P Relay Test Circuit tica i elie adi laa id gese Gad Se ask die 4 9 PN 150P Relay with Molded Driver A 3 Old Style Mounting Base sis ses EE besoe eke e coke be ee ens Fu c sade geb n an bee elo ged A 5 Improved Mounting Base for PN 150P Relays iii ees esse ee ee ee ee ee Ge Re ee Ge ke ee ee ke ee ee ee ke ee A 7 List of Tables Electrical ee Mee 1 2 Adjustment and Calibration Summary for PN 150P Power Transfer Relays 4 12 PN 150P 4 Point Calibration Values ssseeeeee emnes 4 12 Parts List for External Rectifier Kit A 28067 A 8 Parts List for Rectifier Assembly NAb 7 371
7. 4 8 75 4 2 SM 4596F August 1986 Rev 0 N Ansaldo STS APPENDIX A PARTS LIST A 1 Parts List for PN 150P Relays with Molded Drivers See Figure A 1 Appendix A Parts List ITEM DESCRIPTION PART NUMBER 1 Frame Relay N438410 001 2 Rod Latch M388888 3 Washer M437208 4 Spring Coil M263919 5 Latch M321728 6 Dowel Pin J048716 7 Spring M321861 8 Armature N344118 001 9 Washer M291657 10 Screw 46 32 x 7 16 Fil Hd J052243 11 Block Contact 702 703 803 N428420 11 Block Contact 704 705 806 N438966 12 Screw 6 32 x 3 4 Phillips Fil Hd Mach TP J522168 13 Arm Molded Operating M373632 001 14 Indicator M321894 002 15 Lock Nut M438415 16 Screw Spring Guide M310328 001 17 Magnet Permanent M344418 18 Strap M321853 19 Lock Bolt J792919 20 Screw J463078 21 Handle J561111 22 Washer Lock 10 Int Tooth Ph B2 NP J047710 23 Screw 10 32 x 3 8 Phillips Pan Rd Stl Cad P J525277 24 Coil Relay N322508 702 704 N333975 24 Coil Relay N322508 703 705 N321647 24 Coil Relay N322508 803 806 N433498 25 Deleted 26 Tubing 702 703 803 A578438 27 Screw 1 4 20 x 3 4 Hex Cap Stl TP J050016 28 Screw 4 40 x 3 16 Rd Stl F J525024 29 Plate Name M451496 6401 30 Pin Indexing J487090 31 Gasket J047081 32 Cover J776596 33 Washer 0 170 ID
8. NX NX OR 3 i Ed A N Figure 2 4 Typical Circuit Application of PN 150P Power Transfer Relay in Highway Crossing Scheme Utilizing Special Stick Circuit SM 4596F August 1986 Rev 0 2 7 Sd EN Ansaldo STS Installation INTERNAL RECTIFIER r EXTERNAL gt JUMPERS EN NOTE CONTACTS SHOWN ARE FOR 4 POINT RELAY 2F 2H STICK CONTACT Figure 2 5 Wiring of Contact Block 2 8 SM 4596F August 1986 Rev 0 Ansaldo STS Field Maintenance 3 FIELD MAINTENANCE 3 1 INTRODUCTION This section provides the necessary periodic preventive maintenance procedures which must be performed to ensure continuous proper and efficient operation of the PN 150P relays covered in this manual Field maintenance covers periodic inspections and performance tests 3 2 PERIODIC PERFORMANCE TEST 3 2 1 Cleaning Before inspecting and testing the relay if necessary use a soft cloth to clean the exterior to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water may be used for removal of accumulated dirt grease etc 3 2 2 Service Requirements 3 2 2 1 General All vital relays must be inspected and tested at least once every four 4 years The tests and inspections are to include pick up current drop away current timing of slow operatin
9. P1 Stl J475199 34 Deleted 35 Screw J522042 001 36 Wire Seal N330681 0802 37 Seal N330681 0803 38 Deleted 39 Tag Calibration S003665 40 Nut 6 32 Stl Hex 702 703 803 J048148 41 Parts Bag Relay N322508 702 N330681 0802 41 Parts Bag Relay N322508 703 N330681 0803 41 Parts Bag Relay N322508 803 N330681 0803 41 Parts Bag Relay N322508 704 N330681 0806 41 Parts Bag Relay N322508 705 M399568 41 Parts Bag Relay N322508 806 M349785 001 42 Insulation Tubing 702 703 803 M399568 SM 4596F August 1986 Rev 0 Appendix A Parts List DESCRIPTION Ansaldo STS PART NUMBER Spring Operating Arm M349785 001 Washer J047713 Spacer Magnet as required M347526 Counterweight M451176 0401 Seal Vent J790257 Nut Lock M451574 0101 Tag M451496 6201 spacer M451446 1801 Plate Adjustment M451446 1701 Screw 6 32 x 13 16 Hex Cap Stl M341634 Pin Roll J487087 Deleted Screw 6 32 x 5 8 Rd Ed J525601 Rectifier 702 703 803 J726510 0123 Washer Int Lock 6 J047713 SM 4596F August 1986 Rev 0 H KN ER i WL MOO LOWINO 30 WYHOYIY ONIY 30 ONINM3Q10S TYOId AL ovn M3ONI4 19Y1NOO Appendix A Parts List W3i41234 NOOMS A al OWL 4 Ei P SITE IMA E A JI DEON E H OY GLE X un E PIPE OVL 3u 1Y19N3NON e WIN
10. cloth and alcohol Proceed with stop pin and relay contact cleaning using the following recommended cleaning materials Recommended Cleaning Materials Order Reference A relay contact cleaning kit part number X451646 0901 is available that consists of the following three items or which may be ordered individually Burnishing Tool P K Neuses Co No 3 316 3397187 pkg of 5 Burnishing Tool P K Neuses Co No N318 Heavy Duty J397187 001 pkg of 5 Paper Strip strips cut from 67 pound white Springhill Vellum Bristol Paper 5793094 pkg of 50 Also recommended commercially available Emery Paper Wet or Dry 600 Grit cut in strips commercially available Freon TF Miller Stephenson MS180 commercially available Stop Pin Conditioning Graphite Stick N4521151 3203 4 2 1 Armature Stop Pin Conditioning The following instructions are for cleaning the armature stop pin See Figure 4 1 This procedure should be followed wherever a relay is shopped for failure to meet its calibration specifications during scheduled field inspection and tests SM 4596F August 1986 Rev 0 4 1 77 Ansaldo STS Shop Maintenance a After removing the cover clean the stop pin and adjacent surface by saturating a paper strip contained in J793094 with Freon TF and then placing it between the armature and pole face Apply moderate pressure on the armature and draw the paper out Continue until no residue is removed from the surfa
11. given in Table 4 2 i Immediately after 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 S1 OFF 9 O AC 120 VAC Ti M1 POWER 60HZ T2 TRANSFER ISOLATED RELAY LINE UNDER TEST 12 6 VAC PC Figure 4 4 PN 150P Relay Test Circuit j Continue increasing current until the armature picks up to close the front contacts moving to the stop pin at the same energization value The voltage at which this occurs should not be more than that specified in the calibration tables for Pick Up and Working 4 6 4 Hold Down Torque After the relay has been adjusted to meet calibration requirements the force required to move the armature away from the permanent magnet extension should be approximately 250 grams for the SM 4596F August 1986 Rev 0 4 9 77 Ansaldo STS Shop Maintenance 4 point relays This value should be measured at the bottom and center of the molded driver and is the upward force in grams required to move the armature
12. mid stroke neither fronts nor backs touching the driver must be removed and the heel spring driver clip must be adjusted to 0 094 to 0 100 between the top of the dimple and the bottom of the heel springs Adjustment Procedure a b a o mo rh o Hie Plug relay into appropriate mounting base on test stand Check heel springs for bow and adjust as reguired Place contact driver in position on relay Insert front contact closed spacer per Table No I over main stop pin NOTE The value for the stick contact spacer is also given in Table 4 1 Adjust front contacts to touch Insert back closed contact spacer marked per Table 4 lover main stop pin Adjust back contacts to touch Pull contact driver from relay Tool N451151 2801 Bend heel springs to approximately 0 005 min from front contact light perceptible Check that heel springs are approximately in line Place driver on relay Use front closed spacer per Table 4 1 and adjust front contacts to just close 0 048 typically Remove spacer and replace with front open spacer per Table 4 1 and adjust front contacts to just open 0 043 typically Note the value for the stick contact also Remove spacer and replace with back close spacer per Table 4 1 and adjust back contacts to just closed 0 086 typically SM 4596F August 1986 Rev 0 4 7 77 Ansaldo STS Shop Maintenance n Remove spacer and replace with back open spacer per Tabl
13. the latch rod After the relay is completely seated in the base release the latch rod and pull on the handle to ensure that the relay has locked in place SM 4596F August 1986 Rev 0 2 5 SA Ansaldo STS Installation A y 2 7 Stick Contact A standard low voltage contact has been added at 2F 2H B7 B8 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 CAUTION Equipment damage may result if the stick contact is employed for any purpose other than its intended use 2 7 1 Typical Circuit Application The PN 150P 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 4 marked 2F 2H in Figure 2 4 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 150P relay This would cause an inter
14. 2501 A 8 August 1986 Rev 0 V 7 Ansaldo STS Table of Contents N Ansaldo STS A Finmeccanica Company vi SM 4596F August 1986 Rev 0 Ansaldo STS General Information 1 GENERAL INFORMATION 1 1 INTRODUCTION This manual provides service information for the PN 150P plug in relay The PN 150P relay is a biased relay with a built in or external rectifier for use on AC This relay is used to detect the presence of AC power and to switch equipment over to standby power when AC is not present The design of the PN 150P relay conforms to all applicable AAR specifications 1 2 DESCRIPTION 1 2 1 General The PN 150P power transfer relays are basically DC relays with a built in or external rectifier which enables them to be operated on AC voltage The relay is factory calibrated to operate across a wide environmental range All moving parts are enclosed in a sturdy transparent dust and moisture resistant cover To ensure the relay is inserted in its proper mounting base all relays have indexing pins Relays lock securely in the plug in position 1 2 2 Coils Coil resistances of PN 150P relay are depending on part number 240 or 400 ohms Refer to paragraph 1 3 1 to correlate part numbers to coil resistance values The resistance selected depends on system voltage and circuitry 1 2 3 Contacts Contacts of the PN 150P relay are heavy duty low voltage L V silver to silver impregnated carbon front and ba
15. 4 705 and 806 respectively SM 4596F August 1986 Rev 0 3 1 AV r s Ansaldo STS Field Maintenance This repair causes the internal rectifier to be no longer functional and can be done in an emergency however it is recommended that the relay part number be changed along with the indexing and index plate so that the relay cannot be placed into a base that has not been modified a Remove the external wire jumpers from A to C and from A to C and discard See Figure 3 1 b Remove the external AC wiring from the AC spaces and then complete the Rectifier Assembly Installation procedure found in Section 2 5 INTERNAL RECTIFIER EXTERNAL gt JUMPERS REMOVE AND DISCARD EXTERNAL AC WIRING Figure 3 1 Relay Base Before Wiring 3 2 SM 4596F August 1986 Rev 0 SA Ansaldo STS d i y Field Maintenance 3 3 2 Relays with Defective External Rectifiers After it has been determined that the failure of the relay is due to a defective rectifier assembly a Disconnect the two leads Figure 2 3 Item 60 and the two leads Figure 2 3 Items 50 and 55 from the rectifier assembly b Remove the two mounting screws and hardware Replace the defective assembly with a new one and attach with the hardware c Reconnect the red and black leads 50 and 55 d Perform a calibration ch
16. 551 N PN 150BC SM4551 K PN 150BC SM4596 C PN 150BD SM4551 D PN 150BE SM4551L PN 150BE SM4551 P PN 150BE SM4551 Q PN 150BH SM4551 R PN 150BH SM4551 T PN 150BH SM4551 V PN 150BL SM4551 J PN 150BL SM6144 PN 150BM SM4551 M PN 150BSR SM4551 C SM 4596F August 1986 Rev 0 MN 1 N EN Ansaldo STS Maintenance Notice Should a relay fail to meet its calibration specifications during field inspection and test periods as required by FRA Rules Standards and Instructions the relay must be shopped In this event the following supplemental stop pin cleaning instructions should be followed Ref Figure A 1 After removing the cover clean the Stop Pin and adjacent surface by saturating a Paper Strip contained in J793094 with Freon TF and then placing it between the armature and pole face Apply moderate pressure on the armature and draw the paper out Continue until no residue is removed from the surfaces Dry the surfaces using a clean strip of paper 2 The next step is to apply a dry lubricant such as graphite to the relay stop pin and its point of contact on the frame a Insert the Stop Pin conditioning Graphite Stick N451151 3203 between the armature stop pin and its point of contact on the pole face with graphite against stop pin While applying moderate pressure on the stick pull the stick back and forth in a circular motion over the stop pin continuing several seconds to ensure a sufficient amount of graphite transf
17. 8002 Tag Relay Indent J075951 Sheet Instr Form 8 S000008 Bag Plastic J078399 NOTE A Bag Contains When mounting base complete is ordered a plastic bag of parts is included in the inner carton with the mounting base and instruction prints Tags Item 10 Screws Item 6 Items 6 7 8 and 9 which are used for attaching the mounting base to the rack Included receptacle contact springs are normally M451142 2702 for 14 and 16 wire unless otherwise specified If other wire size is used the proper part number M451142 2701 for 18 20 M451142 2703 for 10 12 should be specified when ordering the complete base N451376 0302 except using receptacle contact springs solderless M451142 2703 SM 4596F August 1986 Rev 0 Ei 77 Ansaldo STS A Finmeccanica Company Appendix A Parts List Figure A 3 Improved Mounting Base for PN 150P Relays SM 4596F August 1986 Rev 0 A 7 Appendix A Parts List Ansaldo STS Table 4 3 Parts List for External Rectifier Kit X438967 DESCRIPTION PART NUMBER Rectifier Assembly N451131 3501 Screw 6 32 x 3 8 Rd Hd Stl J525031 Washer 6 FIt Stl J047996 Washer 6 Lock Bz J047708 Screw 8 32 x 3 8 Rd Rd Stl J525128 Washer 8 FIt Stl J047745 Washer 8 Lock J047709 Receptacle Contact Spring M451142 2702 Receptacle Contact Spring J680165 Lead Bl
18. ED ese ENE ee 4 6 4 5 5 1 General 4 6 4 5 5 2 Heel Contact Springs ii EE KERE y e i REEF OR dina GEWER GE HIR ee Re pees 4 6 4 5 5 3 Relays with Molded Drivers iese see ee ee ee ee ee ke ee Ge Re ee ee ke ee ee ke ee ee ee ke ee ee 4 7 4 9 5 4 Contact Openings E 4 8 4 6 Calibration ME EE EE ER OE EE EE EE 4 8 4 6 1 Recommended Test Equipment ese sees ese se ee ee ee ee ee Ee RA ee ee ee ee ee ee ee ee enne 4 8 ME ER OO RO EE nee NE N 4 8 Sd Meri m 4 8 4 6 4 Hold Down Torque see ese ee ee ee Re Re Ge ee GE Ge AA ee ee enne nennen ee ee ee nennen ee ee nennen 4 9 4 65 Contact ResISLance i et ceti n etd Dee M qu VR ATE ER AR RR XR ERA Ue senate Ve 4 10 4 7 MODIFICATIONS ee ee ee erent ee canon rr rra enne eee Re ee ndn Re rr ran neri nennen ine nnn eren nennen 4 10 4 7 1 External Rectifier Relay Retrofit Kit SAD11371 2601 4 10 4 7 2 Parts List Apn113 1 2001 4 11 APPENDIX A PARIS LIST unica A 1 A 1 Parts List for PN 150P Relays with Molded Drivers ee ke ee ee ee A 1 A 2 Parts List for Old Style Mounting Base A d 4 8 Parts List for Improved Mounting Base for PN 150P Relays iese ees se ee ee ke ee ee ke ee ee ee A 6 SM 4596F August 1986 Rev 0 Ansaldo STS Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure A 1 Figure A 2 Figure A 3 Table 1 1 Table 4 1 Table 4 2 Table 4 3 Table
19. Ee eee 2 1 2 2 ed ad ed t RE N EE EE ON 2 1 2 3 EEN dl node EE OE EN 2 1 24 RECEPTACLE CONTACT SPRINGS sesde se ee ee ee ee ee ee ee ee nene ee ee ee ee ee ee ee de ee ee ee rara 2 2 24 1 Old Style Base Only EE IE N N ER EE at 2 2 2 4 2 Improved One Piece Base Only ee Re AR AA AR AA eene eene 2 2 2 4 3 Installing Wires in Receptacle Contact SDringS sesse ee Ee ee AA ee Ge AA ee ee 2 4 2 5 Rectifier Assembly Installation see se ee AA AE ee ee Ee rene 2 4 2 0 Relay Insertion ie re ed een i EE EE aves 2 5 2r oie de ER ER RE AE EE 2 6 2 7 1 Typical Circuit Application rne 2 6 2 1 2 Contact Block n iet e teet vest bte cei e eaa EE N 2 6 3 FIELD MAINTENANCE ssse ei EE eek EER rore tette a Rn REDE Rn AE MEER RR RARE EER Ras EE ER 3 1 Site INTRODUCTION coi 3 1 3 2 PERIODIC PERFORMANCE TEST sees ee ees ee ee ge ee ee ee nc cnn nar cnn ee ee rr ee ee ee ge ee ee ee ge ee ee ee nnns 3 1 AM e EER EE ER N 3 1 3 2 2 Service Reduirements EE SENSE SR GE REK enn Se GE N aed de Se SR REKE Gee dd 3 1 3 2 2 1 Genera 3 1 3 2 2 2 n Service TOS eee E e EE io nd Ho dp ee Rien dro see 3 1 3 2 2 3 Test siele To Vi iret OE EE OE ER a 3 1 Side REPAIR e AR EET AE RE EE RE OE R 3 1 3 3 1 Relays with Defective Internal Rectifiers A 3 1 3 3 2 Relays with Defective External Rectifiers ie ee ee ee AR ee AR ee AR ee ee nn 3 3 4 SHOP MAINTENANCE EE EE EE EE EN 4 1 4 1 INTRODUCTION is ESE Ge asad cen ge eek se
20. O 43H YO4 utt o ET e CH FA Oj c E lt X lt A 3 Figure A 1 PN 150P Relay with Molded Driver SM 4596F August 1986 Rev 0 Ansaldo STS Appendix A Parts List A 2 Parts List for Old Style Mounting Base See Figure A 2 DESCRIPTION PART NUMBER Base Complete N438562 Base Only N38562 099 Receptacle Contact Springs Solderless Type for 18 to 820 Wire 9 yp J680179 Receptacle Contact Springs Solderless Type for 14 to 16 Wire Receptacle Contact Springs Solderless Type for 10 to io ue Pang yp J680181 Base Basic Mounting J078455 Plate Contact Clamping Order should specify part number of mounting base for which contact clamping J078458 plate is desired Plate Coil Clamping Order should specify part number of d J078459 mounting base for which coil clamping plate is desired Strike M321745 Tag J075828 Screw 4 x 3 16 Rd Hd J052674 Screws 1 4 20 x 1 1 4 Rd Hd Not Shown J052667 Washer Lock Not Shown J047775 Washers Plate 1 4 Stl J047501 Nut 1 4 Not Shown J048002 Deleted Screw 6 32 x 1 1 4 Fil Hd S Mach J052246 Nut M267499 Screw 6 32 x 5 8 Fil Hd S Mach J522090 Indexing Plate Relay N322501 702 M322078 0101 Indexing Plate Relay N322501 703 M322078 0102 Indexing Plate Relay N322501 803 M322078 0104 Meter Test Plug N322965 Insulated Test Plug For opening any coil or contact J077931 circuit and for removing receptacle springs J680165
21. ack 6 1 2 N397832 005 Lead Red 6 1 2 N397832 004 Lead White 4 N395673 Print Drawing D451131 36 Table 4 4 Parts List for Rectifier Assembly N451131 3501 DESCRIPTION PART NUMBER PC Mounting Board M451451 3601 Lead M436836 Bridge Rectifier Sil J726150 0123 Screw 4 40 x 5 8 Fl Hd Stl J521089 Washer 4 FI Stl J047640 Washer 4 Lock J047829 Varistor 82 VDC V82ZZA12 J735528 Terminal Cambion J730940 Rivet 1 8 Pop J490037 0014 Terminal Dual Connector J731399 0015 Wire Bare Tinned 14 A043241 Nut 4 40 Hex Stl J480006 SM 4596F August 1986 Rev 0 Ansaldo STS 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 SM 4596F MAINTENANCE NOTICE PLUG IN RELAY ARMATURE STOP PIN CLEANING THIS NOTICE APPLIES TO THE FOLLOWING LIST OF RELAYS Relay Manual PN 150BTR SM4596 A PN 150HD SM4551 E PN 150HD SM4596 E PN 150N SM4551 B PN 150N SM4596 X PN 150NE SM4551 S PN 150P SM4551 F PN 150P SM4596 F PN 150T SM4587 PN 156 SM4593 PN 250B SM4563 E PN 250BE SM4563 PN 258B SM4563 C PN 258BSR SM4563 B PN 259BSR SM4563 D PN 259SRA SM4563 H Relay Manual PN 150B SM4551 PN 150B SM4551 A PN 150B SM4551 H PN 150B SM4
22. away from the permanent magnet When measured the value must not be less than the value given in Table 4 1 4 6 5 Contact Resistance Resistance of front contacts should be measured with the armature in its full stroke position and resistance of back contacts should be measured with the armature fully released Cleaned contact resistance should not exceed the following values Type of Contacts Ohms Front Contacts Ohms Back Contacts Silver to Silver Impregnated Carbon 0 09 Heavy Duty Silver to Silver Impregnated Carbon 0 09 0 05 4 7 MODIFICATIONS 4 7 1 External Rectifier Relay Retrofit Kit X451131 3601 Existing PN 150P relays with internal rectifiers can be modified to have an external rectifier attached to the mounting base Relays with part numbers N322508 702 703 and 803 can be converted to N322508 704 705 and 806 respectively This is accomplished by rewiring the base and mounting the external rectifier The procedure used is given in Section 3 3 1 This rewiring causes the internal rectifier to be no longer functional and the relay part number indexing and index plate must be changed so that the relay cannot be installed in a base that has not been modified In the Relay Retro Fit Kit X451131 3601 is a new name plate index plate and index pin Stamp the new part number on the name plate Remove the index pin in the number 2 or 3 location depending on the relay to be revised Using the new index plate as a gu
23. ces Dry the surfaces using a clean strip of paper b The next step is to apply a dry lubricant such as graphite to the relay stop pin and its point of contact on the pole face 1 Insert the Stop Pin Conditioning Graphite Stick N451151 3203 between the armature stop pin and its point of contact on the pole face with graphite against stop pin While applying moderate pressure on the stick pull the stick back and forth in a circular motion over the stop pin continuing several seconds to ensure a sufficient amount of graphite transfer It is not necessary to observe a significant deposit of graphite since most of what is required can only be determined by means of a microscope c Recheck relay calibration and prepare relay for return to service 4 2 2 Cleaning Relay Contacts This section covers recommended methods for the preparation and cleaning of relay contacts After contacts have been dressed and or after adjustments have been made to meet calibration requirements the contacts should be cleaned in accordance with the following procedures CAUTION The following Caution statement is only mandatory for clear Lexan molded drivers Deviation from this may result in damage to the equipment If 1t is desired to use an aerosol spray for cleaning relay contacts only virgin Freon TF available from Miller Stephenson Chemical Co as MS 180 or MS 230 contact RE NU FREON TF is approved by ASTS USA for cleaning contacts with the driver
24. ck The S Stick 2 contact of this relay is a standard duty contact designed to open slightly in advance of the other contacts The purpose of this advance opening is to eliminate intermittent opening and closing of the power contacts due to high resistance or poor power supply regulation CAUTION Equipment damage may result if the S 2 contact is employed for any purpose other than its intended use 1 3 SPECIFICATIONS The following subsections provide the electrical and mechanical specifications of the power transfer relays covered in this manual SM 4596F August 1986 Rev 0 1 1 General Information 1 3 1 Electrical N 77 Ansaldo STS Relay electrical specifications are tabulated below Table 1 1 Electrical Specifications Part Number Fart Number With Without Front Sol Energization Normal AC Front Testing Testi Contacts Resistance Volt Volt N322508 esto Ohms ol one N322508 702 704 AFB H D 8 1F 240 9 0 10 703 705 803 806 MFBH D amp 1F 400 108 12 These relays are presently furnished with a Lexan cover Contacts Heavy duty low voltage silver to silver impregnated carbon front and back Stick contact 2 is Std L V Contact Assignments Arrangement Numbers 4FB 1 4 5 6 IF LV Stick 2 Note Relays N322508 704 705 and 806 have the rectifier assembly mounted external to the relay X438967 must be ordered separately for new installati
25. d proceed as follows using the referenced values for the specific relay given in Table 4 2 a Set switch S1 to the OFF position b Set voltmeter M1 to appropriate AC voltage range Refer to Table 4 2 c Set Variac output control to minimum output setting d Connect circuit to 120 VAC 60Hz line Set switch S1 to the ON position f Adjust Variac output control up to but no higher than the Normal Charge voltage level as given in Table 4 2 where relay energizes and armature picks up through full stroke 4 8 SM 4596F August 1986 Rev 0 Ansaldo STS Shop Maintenance g Slowly decrease the Variac output until the armature just causes the front contacts to open and back contacts to close Voltmeter M1 should indicate between the dropaway voltage limits given in Table 4 2 NOTE Drop away and Hesitation When measuring the drop away it shall be considered acceptable to have the armature stop pin move away from its pole piece by 0 005 inches and not go to full release However after once the armature begins to move after further reduction in voltage it must without any hesitation transfer from the front to the back contacts A hesitation or hang is defined as the front contacts being closed with little or no contact pressure h Further decrease the Variac output until the full back contact compression is achieved The voltmeter M1 should indicate no less than the dropaway with full back contact compression voltage
26. dexing plate that is applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with indexing plate is shown in Figure 2 1 The following data defines the indexing that has been established for relays covered by this manual a 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 b 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 The 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 c 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 that 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 part number Discard the indexing plate that comes in a bag tied to the handle of all new relays unless it is needed for replacement of damaged ind
27. e 4 1 and adjust back contacts to just open 0 081 typically o Check to see if heels are floating Adjust heel clip as required 4 5 5 4 Contact Openings In obtaining proper calibration it is permissible to vary the adjustments given in the foregoing paragraphs however a With the armature in its fully released position the front contacts must be open at least 0 050 inch b When a front contact is just making the corresponding back contact must be open more than 0 020 inch 4 6 Calibration 4 6 1 Recommended Test Equipment Nomenclature Part Model Type Number Filament Transformer 120 VAC Primary 12 6 VAC Secondary Variable Transformer Variac 120 VAC 60Hz input Digital Multimeter HP3435A 4 6 2 General 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 Table 4 2 If the relay does not meet the calibration value readjust the shunt to give a hold down force in Table 4 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 4 6 3 Procedure Connect power transfer relay test circuit as shown in Figure 4 4 an
28. eck Section 4 6 and if the relay meets the calibration values press the remaining two Faston connectors onto the lower two terminals of the rectifier assembly thereby connecting the relay into service SM 4596F August 1986 Rev 0 3 3 ay 7 Ansaldo STS Field Maintenance N Ansaldo STS A Finmeccanica Company 3 4 SM 4596F August 1986 Rev 0 77 Ansaldo STS Shop Maintenance 4 SHOP MAINTENANCE 4 1 INTRODUCTION This section provides the information necessary to perform shop level repairs of the PN 150P relays covered in this manual In general relays arriving at the shop for repair have been checked in the field and have been found to perform unacceptably or have been physically damaged 4 2 CLEANING AND INSPECTION Before inspecting the relay and initiating repairs use a soft cloth to clean the exterior carefully to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc Inspect the relay exterior for signs of physical damage such as cracked or broken cover cracked or damaged housing and damaged and or missing contact block terminals and indexing pins If severe damage is found a careful inspection of the interior components should be made for physical damage Remove the cover and clean the surface between the armature and the pole faces especially the stop pin area using a lint free
29. er It is not necessary to observe significant deposits of graphite since most of what is required can only be determined by means of a microscope 3 Recheck the relay calibration and prepare the relay for return to service SEE ENLARGED AREA Figure A MN 2 SM 4596F August 1986 Rev 0 N 7 Ansaldo STS inmeccanica Comp Maintenance Notice N Ansaldo STS A Finmeccanica Company SM 4596F August 1986 Rev 0 MN 3 NV 7 Ansaldo STS Maintenance Notice A Finmeccanica Company SA Ansaldo STS A Finmeccanica Company End of Document MN 4 SM 4596F August 1986 Rev 0
30. exing plate or for application to a new mounting base SM 4596F August 1986 Rev 0 2 1 77 Ansaldo STS Installation Never drill new holes in a base indexing plate which will permit application of relays with different part numbers or change indexing pins on the back of a relay unless it is being converted to a new part number Otherwise a hazard will be created which may compromise safety circuit functions 2 4 RECEPTACLE CONTACT SPRINGS 2 4 1 Old Style Base Only The mounting base will normally be equipped with the required quantity of J680165 solderless receptacle contact springs and will accommodate one or two 14 or 16 wires It can however be equipped with receptacle contact springs for one or two 10 or 12 wires J680181 or for one or two 18 or 20 wires J680179 Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation 2 4 2 Improved One Piece Base Only The one piece mounting base with hardware N451376 0302 includes a full complement of receptacle contact springs M451142 2702 to accommodate one or two 714 716 wires mounting fasteners and tags It can however be equipped with receptacle contact springs for one or two 710 212 wires M451142 2703 or for one or two 18 220 M451142 2701 Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation
31. g and timing relays and visual inspection of contacts for damage or misalignment corrosion or other contamination of parts loose parts inside of the cover broken seal and cracked or broken cover All vital relays installed in locomotive or car carried equipment are to be removed from service and adjusted repaired and tested at least once every six 6 years 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 ASTS USA specifications 3 2 2 2 In Service Test It is recommended that line relays in service be removed from service for shop repairs when one or more of the following conditions occur Use as a reference the calibration values given in Table 4 2 a Ifthe Drop Away value D A falls below 90 of the new relay value b Ifthe Pick Up value increases to more than 110 of the new relay value 3 2 2 3 Test Procedures Test the operating characteristics of the PN 150P relays as given in Section 4 6 Calibration 3 3 REPAIR 3 3 1 Relays with Defective Internal Rectifiers If it is found that a PN 150P relay failure is due to a defective internal rectifier a relay retro fit kit X451131 3601 can be used to disconnect the internal defective rectifier and mount its replacement externally on the mounting base This will convert relays with part numbers N322508 702 703 and 803 to relay part numbers N322508 70
32. his relay The permanent magnet assembly should be applied to the relay as shown in Figure 4 2 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 4 5 ADJUSTMENTS All adjusting and testing must be done with the relay in its normal operating position 4 5 1 Recommended Tools and Test Equipment tem Part Number Gap Gauge 0 001 in to 0 200 in Gram Gauge 40 350 Grams Driver Removal Tool N451151 2801 Bending Tool J397164 0039 4 5 2 Armature Air Gap The armature air gap is the distance from armature to pole face with the stop pin against the pole face It should not at any point be less than 0 038 minus 0 002 At the stop pin light must not be visible across more than 25 of the diameter of the pin Light must be visible between the hinge plate on the armature and the forward pole face Safety stop pins should have minimum of 0 001 inch clearance when the armature is at full stroke 4 5 3 Armature Stroke Armature stroke is the distance from stop pin to pole face with the armature resting against the permanent magnet assembly Assemble the magnet to the relay frame with the magnet held against the small step in the pole face using a steel screw on the left side and a brass screw on the right side With a spacer between stop pin and pole face equal to the val
33. ide drill a 42 hole 1 4 deep at the appropriate new pin location and insert the pin After modifying the relay a calibration check Section 4 6 must be made using an externally mounted rectifier It is recommended that a rectifier board N451131 3501 be available in the shop for calibration purposes 4 10 SM 4596F August 1986 Rev 0 N Ansaldo STS 4 7 2 Parts List X451131 360 See Figure 2 3 Description Shop Maintenance Part Number Rectifier Assembly N451131 3501 Screw 6 32 x 3 8 Rd Hd Stl J525031 Washer 6 FIt Stl J047996 Washer 6 Lock Bz J047708 Screw 8 32 x 3 8 Rd Hd Stl J525128 Washer 8 Fit Stl J047745 Washer 8 Lock J047709 Receptacle Contact Spring M451142 2702 Receptacle Contact Spring J680165 Lead Black 6 1 2 N397832 005 Lead Red 6 1 2 N397832 004 Lead White 4 N395673 Index Plate J078457 Name Plate M451496 6401 Print Drawing D451131 36 Index Pin SM 4596F August 1986 Rev 0 J487090 Shop Maintenance Ansaldo STS Table 4 1 Adjustment and Calibration Summary for PN 150P Power Transfer Relays 4 Point Relay Test Number NominalMinimumMaximum Remarks Permanent Magnet Assembly 0 149 0 135 0 155 Main Stop Pin Spacer For Adjustment Back Stop Pins Touching Front Contact Adjustment 9093
34. is impossible to take into account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved ASTS USA spare parts are used as replacements Copyright 2013 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA USA 15219 3120 645 Russell Street Batesburg SC 29006 www ansaldo sts com All rights reserved SM 4596F August 1986 Rev 0 Ansaldo STS Revision History Revision History ISSUE DATE REVISION DESCRIPTION July 1980 This service manual supersedes all y previously issued 4596F manuals ii SM 4596F August 1986 Rev 0 Ansaldo STS Table of Contents Table of Contents 1 GENERAL INFORMATION siese iek seer EE re ee RE occu tu be ee EKKE Ge EE RE Ee ee RENEE EE EE su ce E Rana kun a se EP ege 1 1 1 1 INTRODUCTION ene AR AR ee ee AR ee rr ee ee ee AAN ee ee ee AA nennen a 1 1 1 2 DESCRIPTION p 1 1 Mei RR N 1 1 1 22 Doll EE 1 1 VE COMACIS AR OE EE EE EE EE 1 1 1 3 SPEGCIFICAT EI E 1 1 CAS ale EE RE ER EE HO 1 2 1 3 2 Mechanical 1 2 2 INSTALLATION RE EE EE EE EE EE EE ON 2 1 2 1 GENERAL eerie as ee A ER adie edd old ees
35. mbly Installation See Figure 2 3 NOTE This Rectifier Assembly installation is only necessary for relays N322508 704 705 806 or relays that are to be modified to have external electronic parts Remove the relay from the mounting base Place the Rectifier Assembly into position on the rear of the mounting base and attach using the appropriate 6 or 8 hardware furnished in the kit Select the proper size receptacle contact springs and crimp onto the red and black leads Insert the red lead into the contact space A Al and the black lead into A C1 Press the Faston connectors onto the bridge rectifier red to black to SM 4596F August 1986 Rev 0 Ansaldo STS Installation e Crimp the external AC leads and the white leads onto the proper receptacle contact springs Insert the springs into spaces B A2 and B C2 f Perform a calibration check Section 4 6 and then press the Faston connectors onto the lower PC board terminals k EXTERNAL AC WIRING Figure 2 3 Rectifier Installation Wiring Diagram 2 6 Relay Insertion Orient the relay to the mounting base with the push rod to the left hand side then plug the relay into the base The relay should be pushed firmly against the mounting base while depressing
36. mittent 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 4 is so arranged that when the contact 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 150P relay 2 7 2 Contact Block Wiring the contact block is shown in Figure 2 5 Refer to paragraph 4 4 4 1 in this service manual when replacing the contact block The present relay 702 703 and 803 is not a direct replacement of earlier design relays 002 and 003 The stick contact has been changed from 6 to the 2 location and the mounting base wiring must be changed according to Figure 2 5 2 6 SM 4596F August 1986 Rev 0 Ansaldo STS Installation BX NX ETS A 9 ee BATTERY AC AC A n d a mal ly e Ze c RA C XR PEE SEN OR XTPR A A gt 2H S F Mm eo VY En BX OR N R TG Gi TO LIGHTS A B N AN
37. n the energized position 4 5 5 Contact Adjustment 4 5 5 1 General The fingers supporting the contact springs should be straight and approximately at right angles to the relay base All adjustments of contacts should be made using contact adjusting tool J397164 0039 The contact driver can be removed by using the molded contact driver removal tool N451151 2801 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 Best contact stability is obtained by slightly overbending the spring and returning it to the desired position 4 5 5 2 Heel Contact Springs Before adjusting these heel springs it should be determined that the dimensions exist as shown in Figure 4 3 and that the bifurcated parts have a slight trapped pressure against the main member 4 6 SM 4596F August 1986 Rev 0 77 Ansaldo STS Shop Maintenance 100 094 A e Figure 4 3 Heel Contact Spring 4 5 5 3 Relays with Molded Drivers The contacts are to be adjusted to just touch when using closed spacer As a guide there should be no more than 2 grams spring pressure between the contact tips For any contact adjusted closed using nominal spacers per Table 4 1 a 0 005 thicker spacer for the fronts and a 0 005 thinner spacer for the backs must allow the contacts to be open If the heel springs show free play in the driver slots when the armature is held
38. nstallation N 77 Ansaldo STS 2 4 3 Installing Wires in Receptacle Contact Springs Use the following procedure to ensure a good electrical and mechanical connection between the conductor wire and the receptacle contact spring The following table identifies the correct crimping tool to be used when installing wires in receptacle contact springs Old Style Improved Base Crimping Tool Receptacle Receptacle Contact Spring Contact Spring 3397138 10 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Standard M451142 2702 J397188 18 20 AWG J680179 M451142 2701 Strip 3 16 in 0 187 in or 0 47 cm of insulation from the end of the wire Place the receptacle contact spring into the jaws of the proper crimping tool When using only one terminal of any wire size use the shortest terminal Partially close the crimping tool jaws against the receptacle contact spring to hold it in place Do not crush the receptacle contact spring barrel at this time Insert the stripped end of wire all the way into the receptacle contact spring barrel Squeeze the tool handles until crimping is completed and the jaws release When using both terminals it is more convenient to attach the first wire to the longest terminal Remove the crimped receptacle contact spring from the tool and inspect the connection Make certain that the wire is flush with the crimped barrel and that there are no loose strands of wire 2 5 Rectifier Asse
39. ons 1 3 2 Mechanical The following mechanical specifications are common to all PN 150P relays covered in this manual Relay Dimensions Temperature Indexing Weight Mounting Base Mounting Base Weight Mounting Base Dimensions Height 7 1 16 17 93 cm Width 2 7 16 6 19 cm Depth 8 3 8 21 27 cm 40 F 40 C to 185 F 85 C Refer to Section 2 3 6 3 4 Lbs 3 07 kg N438562 Old Style N451376 0302 Improved Style 17 5 oz Old Style 9 5 oz Improved Style Height 7 15 16 20 16 cm Width 2 7 16 6 19 cm Depth 2 7 16 6 19 cm Old Style Depth 1 25 32 4 52 cm Improved Style SM 4596F August 1986 Rev 0 77 Ansaldo STS Installation 2 INSTALLATION 2 1 GENERAL Relays plug directly into a mounting base that is secured to a rack The only installation instructions required are for the mounting base and the rectifier assembly for those relays designed or modified for external rectifiers 2 2 MOUNTING BASE Secure the mounting base directly to the rack using the hardware furnished All wiring terminates at the rear of the mounting base to solderless terminals receptacle contact springs Mounting base details are shown in Figure A 2 Old Style Base and Figure A 3 Improved Base of the Appendix 2 3 RELAY INDEXING Relays are factory equipped with indexing pins to prevent insertion of an incorrect relay into a mounting base Each relay is accompanied by an in
40. parts in this relay in most cases the relay can be restored to proper operation by dressing Section4 2 2 1 and readjusting Section 4 5 5 them SM 4596F August 1986 Rev 0 4 3 SA 7 Ansaldo STS Shop Maintenance d 4 4 1 Recommended Tools Twist Drill 42 Screw Driver Torque Measuring 4 4 2 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the parts list appendix for part information and location of parts In general to dismantle the plug in relay proceed with the following sequence a Remove relay cover seal b Carefully remove plastic cover Remove disassemble relay components as required a Remove contacts contact block as required e Remove permanent magnet as required NOTE 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 separated from other magnetic objects and the screws which hold the extension to the magnet be kept tight Should a magnet become weakened it should be returned to the factory for recharging where there is special equipment to fully charge the magnet It will then be aged it to its best working strength 4 4 3 Reassembly Reassembly is accomplished generally in the re terse order of disassembly Do not overtighten or force parts when reassembling a relay The following paragraphs provide additional instruction
41. s to be followed during reassembly of this relay Upon completion of reassembly calibrate the relay as directed in paragraph 4 6 4 4 4 General Parts Replacement 4 4 4 1 Replacing 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 0 0935 Dia thru the dowel pin holes into the epoxy contact block for a total depth of 9 16 1 32 0 NOTE Replacement contact blocks MUST be of the same general design 4 4 SM 4596F August 1986 Rev 0 SA Ansaldo STS f i y Shop Maintenance Carefully install the dowel pins tapping in until they are flush with the surface If it is necessary to install a used contact block from another relay remove only one of the dowel pins from the 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 Install the contact block mounting screws and torque them to 10 2 inch pounds Do not overtighten or force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in Section 4 6 4 4 4 2 Permanent Magnet 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 NOTE The magnetic shunt is not used in t
42. ti a eh se Ad Sea sk dig 4 1 4 2 CLEANING AND INSPECTION ee ee ese ee ee ee ee ee ee ee ke ee ee ee ee Ge ke ee ek ee ee ee ee rn ee ee nns 4 1 4 2 1 Armature Stop Pin Condtonimg ees ee ee ee ee Re ee ee nennen 4 1 4 2 2 Cleaning Relay Contacts iese ee ee ee ee nennen ennemis 4 2 4 2 2 1 Contacts That Are Severely Burned ie ee ee ee ee Ge Ke ee ee ke ee 4 3 4 2 2 2 Contacts with Heavy Tarnish Slightly Rough or Pitted iese ees esse se ee ee 4 3 4 2 2 3 Contacts with Surface Film or Oxidation Not Pitted ee ee ee ee 4 3 4 3 CHECK OUT PROCEDURE Performance Test ede esse se ee eee 4 3 SM 4596F August 1986 Rev 0 iii Table of Contents 77 Ansaldo STS 44 REPAIRS AND REPLACEMENT rete idee eee den xe d nde c 4 3 4 4 1 Recommended Tools 4 4 Ee OMV coc ii 4 4 44 3 TREASSOMDIY RR EE EE ORR EE EE ER N 4 4 4 4 4 General Parts Replacement is ee ee ee RA Ee ee ee Ge Ee Re de ee ee ee ee ee ee enne 4 4 4 4 4 1 Replacing Contact Block 4 4 4 4 4 2 Permanent Magnet ie ee ee ee eene enne ee ke ee ee 4 5 4 5 ADJUSTMENTS nno RE AE ER EE 4 5 4 5 1 Recommended Tools and Test EduipmenN ees se se ede ee ee ee Ge AA ee ee ee ee ee Ge manco 4 5 445 2 Armature Air Gap creed ete ES ER ER Ee NS Ee Ee E RA Ee ER A Ge Re Tee ER OES YR Re Ee ees 4 5 4 5 3 Armature otroke 2 ode e li id adi s 4 5 A 4 6 4 5 5 Contact Adjustmoent ee aee coa GE Se
43. ue for Test 1 called for in Table No 1 adjust and tighten the magnet extension to be just touching the two stop pins on the bottom of the armature Magnet hold down screws to be torqued to 15 2 inch pounds SM 4596F August 1986 Rev 0 4 5 77 Ansaldo STS Shop Maintenance With the stop pin spacer removed and the armature released both back stop pins should make contact with the permanent magnet extension over at least 50 of the diameters and neither should project over the edge of the permanent magnet extension In this position the air gap at the permanent magnet extension face should average 0 004 inch parallel and must not be less than 0 003 inch at any point This is the physical air gap from plated magnet extension to plated armature ADJUSTABLE SHUNT NOT USED MAGNET MAGNETIC SHUNT POLE PIECE D zu 7 Ese WER 7 MAGNET EXTENSION 7 REFERENCE A DIMENSIONS Z 7 Y PHOSPHOR BRONZE OR STEEL SCREW AS REQUIRED Figure 4 2 Assembly of Permanent Magnet 4 5 4 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 indicator should be in full view with the armature in the deenergized position and should be hidden with the armature i
Download Pdf Manuals
Related Search