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1 - Ansaldo STS

1. 150 Feet OF THE DQ AO 15 DESILNED BE MECHANK ALLY AND ELECTRICALLY COMPATIBLE With OA SO INSTALLATIONS TT 15 ANTICIPATED THAT THE OR AO Wier INSTALLED AT AAILADAD AROS USING EXISTING DR 30 UNITS ANO THE OLD NEW AN SYSTEMS OPERATING ToLeTHER SEE DRAWING 1 8 4 6 15 AND ADIUSTMENT OF THE OR 15 4 MANDAL GOIS 08 40 13 NORMALLY APPLIFO AS PART GF SPEED Coro SYBTEM USED THE SPEED CONTROL SYSTEM DETECTS THE ING CAR 4 APPLIES THE REQUESTEO NELOSITY THE SPEED AMPLIFIER GINTIATES JRE RADAR START THE CARS ACTUAL VELOCITY THE RADAR GuyPUT SIGNAL OF 31 4 PER MPH 15 APPLIED TO THE NELOCITY METER THE METER CONVERTS THE OUTPUT 10 0 4 IMP THAT 13 ppoto THE SPEED AMPLIFIER THE SPEED AMP CorApARES THE To THE ACTUAL AND EHERGIEES AN AIR EXWWUST RELAY WWCREASING OR DECREASING THE APPLIED To THE RETARDER FoR OPTIMUM OPERATION MAXIMUM SENSITNITTY ANOIO INSTAUANG ORAO NEAR STRONG BROADCAST STATION TOWERS NEON MANS HEAVY POWER LINES IN GENERAL ANY WIC HANE Noisy 8ROADCAST RADIO ARCEBTION 5 d eos ee isi we Gn 8
2. 2 18 19 20 21 224 23 24 25 26 27 28 29 30 3l 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 SECTION VIII PARTS LIST Q UNION SWITCH amp SIGNAL D N451127 0203 For Mtg On 2 Cast Iron Bases N451127 0202 For Mtg On Concrete Base N451127 0201 For Mtg On 2 Cast Iron Bases MAIN ASSEMBLY Reference Figure 8 1 Description BOX Window RF Chassis Gunn Diode Shock Mount Cover Rubber 1 4 x 3 4 Sponge Plate Name Lock Spring Loaded Link Plate Name Ell 2 x 45 Str Galv Sleeve Plate Block Term Washer Nut Nut Binding Sleeve Insl Tag Wht Mkg 1 Tag Wht Mkg 2 Tag Wht Mkg 3 Tag Wht Mkg 4 Tag Wht Mkg 5 Tag Wht Mkg 6 Tag Wht Mkg 7 Tag Wht Mkg 8 Cable Lead Clamp Cable NP 10N Retainer Washer 8 Shprf Lk 1208 Scr 10 32 x 1 2 Flat Stl Scr 1 4 20 x 7 8 Fil Stl Washer 1 4 M S LK Nut 1 4 20 Hex Stl Scr 8 32 x 1 2 Rd Stl Scr 8 32 x 7 16 Flat Stl Washer 8 Stl Plate Washer 8 M Stl Lock Nut 8 32 Hex Stl Scr 4 40 x 1 4 Rd Stl Plate Mtg For 0201 Only Base Mtg For 0202 Only Stud Mtg Cap Moulded Insl Nut 1 2 13 Hex Nut 1 2 13 Elas Top Scr 1 4 x 1 Hes Hd Cap Plate Mtg For 0203 Only Part Number R451128 0901 M451128 1102 N451128 0801 J075467 R451128 1301 A750075 M451425 3402 J562040 M451108 5202 J032603 M2
3. 1 0240 Rapar Onir Parr No 1 NA5127 Oto 1121 02202 FoR FOUNDATION 2 Scuematic Diagram 0451738 SH 1001 3 Wawa Diag gam F451 28 54 8 Evectaicac Du DAS1474 58 02 59 1 OR amp o RADAR SYSTEM 5 Spec EU 5447 QADAW b Sm lois 1 Poor Cunsss N45Vuztg ogo Dug VAsiit8 54 8 8 Daserr Cuassis 451118 0801 049 18 Su 8 Nore DRAG unm most ECC Rues 4 Arion s Paar 93 Tints THE REGUAATED POWER Suppe pRoMIDES Ace THE tieerssaRy VOLTAGES THE 0 5 ELECTRONIC 5 15 NORMALLY OPERATED FRom THE Cammina 1 PousgQ Lines ALL INPUT ANO OuiPOT SisNALS THE TABULATION OF APPLICATIONS Rey No Dua 123 X451474 Ouo 0451474 06 Oursive of Ras Ballast 451414 10 451414 01 Berweent Rans 451474 0801 0451414 108 Berween Rais TuroamaTion 4 Doemer Rana Unit 15 QROOLOCATION SYSTEM USEO TO MEASURE THE VELOCIT OF NEHICLES AT YAQIOUS POINTS ALONG THE RAILROAD TRACKWAY DQ 40 15 RADAR TRANSCEINER UTILIZING CONTINUOUS WAVE 10 526 WITH A RADIO FREQUENCY OUTPUT OF APPROXI MATEY MILLIWATTS DRAG CAN HOUSED ETHER 00
4. ee E 13 m EN WIRE FROM 7 TO SOLDERED To Tris RING GASKET SUPPLIED wirH HORN Figure 8 2 Chassis Mounted Component Location 6015 p 8 7 8 8 3 Item No 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Legend IC1 IC2 3 4 5 6 IC7 IC8 D1 2 4 5 6 7 8 D16 17 18 19 20 9 10 11 D12 13 14 15 DA2 R4 R2 5 6 7 9 10 12 13 17 18 24 25 R3 21 22 23 R8 11 40 R14 23 38 41 R15 16 42 R19 Q UNION SWITCH amp SIGNAL gt P C BOARD N451055 4201 Reference Figure 8 3 Description Ckt Int 4016 Function Quad Package Type C DC Supply Voltage 0 5 to 15 Ckt Int 777DC Function Precision Supply VDC 22 operational amplifiers Ckt Int 4001 Function Quad 2 Inp Package Type DC Supply Volt age 0 5 to 15 Ckt Int 723 Output Voltage 2 0 37 Input Voltage 9 5 40 Diode 1N4742A Vz nom 12 12 ma 21 5 l watt Diode 1N914A PRV 75 VF 1 0 IF 20 IR 5uA Silicon Diode 1N5232 VZ nom 5 6 12 ma 20 5 500 mw Diode 1N5240 VZ nom 10 12T ma 20 5 500 mw Diode 1N4004 VR 400 VF Avg 1 1 Io amps Avg 1 0 Ir ma Avg 10uA Array Diode CA3039 Resistor 510 ohm Mfr AB 5 250 watt Type CB5115 Resistor 5 1K Mfr AB 5 250 watt CB5125 Type Resistor l00K Mfr 5 250 watt CB1045 Type
5. TP16 E EA i COMPOMENTS SHOWN IN THIS SECTION MOUNTED SUS BK ASS Y UNAS1128 0801 x AAR TERMINAL BLOCK LOCATEO WiTHIM RADAR ENCLOSURE CONNECTOR OM UNIT SUPPLIED p GUMM DIODE UNIT R6 R7 5 IK 80v 9V i10 5v V 10 5V 1123 FASTON H3 1 RIA CA303 SHIELD 1 758 FX IE SUPPLIED WITH THE COMPONENTS BY VENDOR 542 44 TPIO Q i 8 RI 4 S iK 14 7 jiz 9 10 5 5 6 5 4 FASTON H amp R23 42 R21 R22 RFK Q it i wn 100K gt f 100K R20 CONTROL S AAR 5 6 5 6 8T ls gt FF F s a a w as a mm r Se 160 R3 C22 190K D 1 R4 ww TPi4 a i 5 9 R32 R31 D20 R2 R5 22 Proceed 100 2 B FASTON Hs 1 30 22 TEST D SIGNAL 2 INPUT 5 6v 2 5 37 Ly A GUNN DIODE SUPP FASTON 1 3 3 10 V DC i 5 i SUPPLY 5 Map Ft cle 35 R33 Ds 1 10K LOK 202 INST 42 R36 16 250MFD T 8 8V DC SUPPLY NOTE N 03 INS252 De 2 015 rn 2 ann
6. 51 46 Y 347 CHEK DETECTION Pc6 45 054 Arso see P Remove Rr Jur AME d THE emery 08 40 GROUND LEAO Room 2 2 AnD REPLACE Sun ASSEMBLY FOLLO Nese f hoo New C 22 INSTRUCTIONS GIVEN IN SEANICE MANUAL 0075 mi 78 gt esr Duo K451238 0303 ADD tF Nore 2 THE EXTRA WARE MUST St REMONED FRom THE 06 30 nats 16 8 IE e ee X q nA STD CABLE ASSEMBLY AS SHOWN IN FIGURE 2t 2 a io CONNECTED 0 5455 4161 Jis poc e Yo F Geen NX 417 Gaounn Rer 3 DX p THESE Wires Test ETO CARO Ficoae B e OL 4309 FROM TERMINAL STRIP 6 ASSURE THAT 528 NASIOS 450l AS lt EACH WIRE 1 PROPERLY INSULATED AND TR Tu M DING TO Rn 225 RELABEL WIRES AT EQUIP ROOM RACK 8 Power CHECK BIAS ACCORDI S6 SPARE JUNCTION BOX AND T A CONNECTOR WIRES Line DRIVER 4451954 Seance Manvar 2015 AS Fouows IN 1 BELOW Q LIS VOLT POWER SUPPLY REQUIRED 1 53 mE gt 003465 9 w
7. LL AA BB Operation Voltage at TP21 GND at Faston 7 Normal Operating Conditions Output at TP22 With 785 Hz Test Signal 6V p p Scope Setting 1 Vert Attn CH 1 0 5 v div 2 Vet Attn CH 2 lt 3 Vert Mode 1 Coupling 4 Horiz Time Base 5 Probe 10 1 Output 91 1 41 2 71 9 GND Scope Setting 1 Vert Attn CH 1 0 2 v div Inverted 2 Vert Attn CH 2 0 2 v div 3 Vert Mode Added Coupling AC 4 Horiz Time Base 2 0 milli sec div 5 Probe 10 1 UNION SWITCH amp SIGNAL gt Verification Dig Voltmeter Reading 7 See Rete Sees ee Ree n AY SEHE SERE 6015 6 31 32 4 UNION SWITCH amp SIGNAL SECTION VII CORRECTIVE MAINTENANCE AND CALIBRATION 7 1 GENERAL REMARKS Refer to Section 6 1 p 6 1 for steps required to pull subassembly chassis from housing and to temporarily relocate horn Gunn Diode unit for PC Board access Refer to Figures 6 6 and 6 7 pages 6 13 6 14 for general chassis wiring and PC Board Faston locations respectively Rating and or other identification information for individual chassis and PC Board components is provided in Section VIII Wiring between chassis components and the PC Board is tagged or color coded to allow correct reconnection when a new
8. 9v DC SUPPLY 77 013 014 R34 210 cao 1 cis 50 T 45 64 DC SUPPLY gt a cia 3 7 D dm 0 2 A lt s s s 10 T 1 5240 129 1 5232 i HVAC FAS el FC0 0 451055 4201 451055 42 FASTON ilio UC451238 1001 DR 40 RADAR UNIT 3 m prenne 8 TYPE III VELAC CLASS YARD STANDARD CIRCUITS i O 8 Lene Re eine MEER CT p T2 A13 I3 IVEN WAT V WISTIRGNSSS YS E x Con dum wh Sema pacts RepRoDUcED i Suits ARO EQUI M LUE KED BV 2 162960 ieu t 45238 el Figure 6 4 Schematic Diagram DR 40 Radar p 6015 p 6 5 6 UNION SWITCH amp SIGNAL D 6 2 3 velocity Measurement Circuitry The DR 40 has a single printed circuit board which utilizes several types of linear and digital integrated circuits The printed circuit board contains a single CD 4016 AE which is a COS MOS Complementary Symmetry Metal Oxide Semiconductor Quad Bilateral Switch Three of the four solid state switches on the single chip are used Each switch is made up of an input an output and a control connection Whenever a positive voltage or a high logic level appears
9. Y smetb EXPANSION SET aaner kroek anrs jw 1 asss m 4 20 HEX STL 41166 AAR TERMINAL STRIP 136 A R E A Rare SEE NOTE A le LINDER TIE 2228 M MLA 1 t i APPLICATION OF INSIDE RAILS FOR General Replication IN FoRMATION 0451414 5 01 i DESCRIPTION PROBAT 489 081133 124 Mam QUA rat iN INCHES davam Pe tsi OF Wpowdat Cte 4 id m three 74 19 199 dau Fractions EE Adee 13 91504 wiitita noo M tui REQ 13 7 9 4 71408 TASES OF OF TE TUT Hei HR of DR 40 Radar Between the Rails On Concrete Foundation TOLERANCES ON FINISHED RM S FINNISH ale eee DIMENSIONS UNLESS 123 OTHERWISE SPECIFIED 2 5 NOTEO D ete jte pe REM M 297522 CN CC eene 22 ZZ 09 04 WABCO UNION SWITCH SIGHAL QUE XT 61775 D B i APPLICATION amp CHARACTERISTIC DW S FOR VELAC DR 40 RADAR 81115104
10. AND COMNEST OTHER ENO To LINE DRIVER AS SHOWU Run i N280 New Conmecrion ANOTHER WIRE FROM OUTPUT OF LINE RETAADER TERM WAL BOARD i D AX a PIN 31 AS SHOWN 14 G IE ATE 5 5 4 GND WIRE DISCONNECTED FROM RETARDER TERMINAL NEAREST ae To Live DRIER AVAILABLE EARTH GND AS SHOWN IN 6 E gt gt gt SY GND 6 Remove EXISTING DR S AND INSTALL NEW DR 4O MAKING CONNECTIONS 5 AS SHOWN Fiure USE EXISTING CABLE E Coun amp ct 300 amo RE NEAREST AVAILAGLE source OF izovAC AT E 23 42 58 5 B6 Qua RETAROER TERMINAL GoARO AS SHOWN 6 2 Do 8 comete Te NSULATE gt gt gt A34 gt gt n Sig 4 sie B Nore unR amp nio ADDED BETWEEN TERMINAL ON AND SIME EEE T EES A30 UNUSED CONNECTOR Pus LABELED M2 J SHOW E k el Css ee E Z tas Tas erst cer DR 5 t lO RF Unit 8 CONNECT NEU WIRE HERE Wes ure K E Ma J N E e CONNECT TO 3 F ETARGER EARTH CRD R Meter RR 1 TERMINAL K 9 12 e c
11. Fog MORE DETAILS SEE NB 9 5815 4 TO CHECKFAIL 2 SELECTED LOCATION REMONE THE 00 20 REPLACE Witty gt DETECTION DR 40 Sug ASSEM Guy FOLLOW INSTRUCTIONS iN SERNice MANUAL 6015 T 10 Nove THE REMNEO FROM THE 08 20 ASSEMBLY ww Figure amp 3 whine BANT AND EARM SEE 2 Figure WiRES ARAY RAK PER CONVERSION TAGUE SEE REP IN A Torr ON Quen Che MIRER To Seade Manya 4015 TO VELOCITY 5 4 RADAR Wor COMPLETELY OPERATIONAL ub es 17228517 METER PANEL 1 14 eh ead IW Conve ON TABLE poca i m PSC Repaces PSC RETROFIT CHASSIS NASIIZ O802 DWG F 45412 9 SH JONES PLUGS Consists OF gt Test 843 5 A GUNN CHASSIS 5 74 0801 OWG FAS1IZ8 SH 8 Test Repiaces FSC SEANCE MANUAL SMLOIS PEA G D REQUIREMENT FIGURE 4 SCREWS 10 324V2 2050480 OBS Uu ue 4 WASHER IO Sp 060 15 1041133 3 5 4 WASHER MO713124 OO 1826 s Itecout ie 3 70158 4 0011 BKWI em STD PCB JUMPER PINS 16 AND 11 3 TAG 7015874 00 72 SPARE t 5 SN FREG STD VAS
12. If no go to step 64 Using the voltages and waveforms supplied perform trouble analysis anD repair the affected supply When repair is made confirm operation with tuning fork test and rfk measurements 5 Connect the Simpson analyzer set on 50VAC range across Faston 9 and Faston 10 Is 24 VAC measured on meter If no go to step 66 Check ground connection at TPl Check bridge rectifier D12 through D15 and all associated track copper When repair is made confirm operation with tuning fork test and rfk measurements STOP Check fuse F2 transformer T4 and all associated wiring and track copper Check wiring between AAR terminal 6 and 21 5 also between AAR 7 and 21 12 Make repair and confirm operation with tuning fork and rfk voltage checks STOP 6015 p 6 22 67 68 69 70 71 72 UNION SWITCH amp SIGNAL Connect test set up shown in Figure 6 5 Set test set up approximately 6 inches in front of the DR 40 s horn antenna Perform procedure 3 2 2 3 steps 2 through 9 Is the Gunn Diode producing rr energy determined by an indication on the power meter If no go to step 69 Put test set up aside Turn power to unit off Check the mixer diode by substituting another mixer diode which is known to be in working condition and of the same type Check also the zener and lk resistor on the Doppler module Does this restore rfk voltage and Doppler output If yes discar
13. Bustine 02 anons dad Bara Cusine EXISTING OR 20 BO N suz7 02 Xx 8 8 9 suit i TOWER Reu Room i i RFK METER 2 FO m 4 RF CASE GROUNDED COND CABLE composite FROM JUNCTION RF Mir FURRISHEO by 3 5 45 Dios Tue Or 40 RADAR WAS Ocsia Oo COMPATIBLE WITH THE 08 10 UNIT THE PHYSICAL SIRE MOUNTING ARRANGEMENTS CAGLE CONNECTIONS FoR THE DRAG UNNS WERE CHOSEN SO THAT VX COULO GE MOUNTED IN AN EXISTING OR 20 ENCLOSURE PACKAGING ALTERATIONS THE SIGNAL INPUTS AMD OUTPUTS OF THE 0R AO UNIT ARE COMPATIBLE WITH THE EXISTING NELAC VAT Speen MEASUREMENT CONTROL EQUIPMENT WITH A MINOR MODIFICATION OF THE CONNECTION 1N THE RACKS THE MAIN OIFFERENCE BETWEEN HE UNITS 15 iN THE POWER Suppe CONNECTIONS 5 PowER SUPPLY 15 REQUIRED THE OR 15 STEP By STEP PROCEDURE FoR RETROFITING 08 40 UNITS AN OR 20 INSTALLATIONS 8 1 we fe gi De to 20 QF Retaorrr ZINstauetion 06 20 Box y Remove Jones PLUG MARKED m Viegax B RELABEL wita TAGS RETROFIT lusratt J SHIELDED CABLE 29 AND LINE DRIVER WITH FREG STD
14. OF RAIL Figure 4 6 DR 40 Radar Horizontal Aiming Adjustments ELASTIC STOP NUTS RADAR UNIT MCUNTING BRACKET Figure 4 7 DR 40 Radar Vertical Aiming Adjustments 6015 p 4 13 14 UNION SWITCH amp SIGNAL SECTION V PERIODIC PREVENTIVE MAINTENANCE 5 6 MONTHS WARNING AC POWER TO THE RADAR UNIT MUST BE DISCONNECTED PRIOR TO CONDUCTING ANY HANDS ON MAINTENANCE OTHERWISE PERSONAL INJURY MAY RESULT 5 1 INSPECTION Make a thorough visual inspection of all wiring and cables for evidence of fraying or burning Also test wires to determine if any have worked loose at their connecting points Check the physical integrity of all other components looking for indi cations of burns and cracks leakage of insulation compounds and general physical damage Also check the structural inte grity of the printed circuit board and the mounting tightness of all integrated circuit packages If any of the above general types of problems are discovered go to Section VI to the appropriate maintenance section 5 2 CLEANING CAUTION DO NOT ATTEMPT TO CLEAN P C BOARDS COMPONENTS OR OTHER SMALL COMPONENTS WITH ANY KIND OF STIFF BRUSH SOLVENTS VACUUM CLEANER OR COM PRESSED AIR OTHERWISE DAMAGE TO THESE COMPON ENTS MAY RESULT l Remove excessive dust from internal surfaces and compon ents using a soft bristle brush and low pressure com pressed air jet 2 Wipe external surfaces with a soft da
15. et roe etn pie 1 167718 EQUIPMENT CHARACTERISTICS mantra im one i l l Saat MM GUAE UN Aerucat iON Notes St US ae UE SG aedi acidic tiae NM FRACTIONS PLACK PLACE GEN MKKY E Fo Ca crams pace gu wae e UNION SWITCN L SIGNAL DIVISION 31 Emm Im pode p Mit on aasma C E Ioa CH u ANGULAR DIMENRONS xit Ps EM duri ARA N g 8 Q 21 22 Figure 10 2 DR 5 10 Radar Replacement with DR 40 Procedures Wiring Modifications and References 6015 10 3 4 ET NT Keue A RF acr Li gt Fig unE mei 11 15 1 5 21 Dero To 08 20 Conriourationl Remove Insucate 21 1 1 15 1 1 LWJ 16 23 78 21 14 T Toncyion Lean JUNCTION Boy Sie E tt 157 8 PIC AL Dr 20 Cikeuit Conrigurdrion 4 i TOWER Room 3 TEST 7 mem S H 4 E pet UNION SWITCH amp SIGNAL Retrorir O Racag Unit
16. v9 m om 6 3 4 1 Horn and Doppler Transceiver Module Components 9 0 Volt 5 6 Volt Components of the Horn Doppler Transceiver Module are analyzed for possible defects via the complete substitution of the faulty unit with another which is known to be in working condition However disassembly for this purpose is restricted to the externally mounted Zener Diode and Schottky Mixer Diode NOTE The Gunn Diode unit must not be removed from the transceiver module for any purpose Doing SO would result in wide output variations and therefore jeopardize FCC type acceptance for the radar and the customer FCC station authorization limits Refer to Section 7 2 1 for allowed disassembly steps for these components and to Section 6 3 5 for allowed troubleshooting procedures CAUTION DO NOT MAKE OHMMETER CHECKS ON THE RF DIODES OR INTEGRATED CIRCUITS DURING BENCH TESTING OTHERWISE DAMAGE TO THESE DEVICES MAY RESULT ALSO THE SCHOTTKY MIXER DIODE IS SUSCEPTIBLE TO DAMAGE BY STATIC ELECTRIC DISCHARGE THE TECHNICIAN SHOULD TAKE STEPS TO DISCHARGE ALL STATIS ELECTRICITY FROM HIS BODY BEFORE HANDLING THESE DIODES THE DIODES WHETHER OR NOT THEY ARE SUSPECTED OF DAMAGE SHOULD BE STORED ONLY IN AN ELECTROSTATICALLY SHIEDED CONTAINER SUCH AS THOSE THEY ARE SHIPPED IN 6015 p 6 10 UNION SWITCH amp SIGNAL D 6 3 4 2 Diodes Other Than RF Diodes may be checked for an open or short by measuring re
17. 13 14 15 Disconnect Digital Voltmeter lead from TP5 and connect it to Faston l Aim unit into maximum un obstructed distance with no movement in unit or tar get area adjust the 2 56 screw on Gunn unit Recheck Gunn Diode frequency Disconnect Digital Voltmeter from TP5 and TP1 Connect Digital Voltmeter to points C and D as indi cated in Figure 6 5 Adjust oscilloscope as follows VERT 5v div HORZ l Msec div SYNC AUTO COUPLING DIRECT Activate tuning fork and place it approximately 3 inches in front of DR 40 horn Adjust audio oscillator for 6V p p at a 785 Hz 5 Hz Sinewave output and connect output to Fastons 8 and ll Reactivate funing fork and place it approximately 3 inches in front of DR 40 horn while simultaneously increasing amplitude of audio oscillator 9A 10 ll 12 13 14 15 END OF TEST 6015 p 7 6 A Minus 4 VDC 05 Retighten locking nut and screw then seal with inspectors lacquer after adjustment with unit in operating position 10 525 GHz 1 0 MHz Greater than 1 0 VDC with 25 feet of unobstructed target area Observe a minimum of 10 p p on oscilloscope Signal on oscilloscope will shift from tuning fork frequency to audio oscillator test frequency when audio oscillator amplitude equals 6V p p 1 p p 8 1 DR 40 Item No OY Ut gt C N H2 Ee 6 gt
18. 4 SERVICE MANUAL 6015 DR 40 RADAR Sept 1979 WP C 79 200 1979 3 UNION SWITCH amp SIGNAL INC 5800 CORPORATE DRIVE e PITTSBURGH PA 15237 UNION SWITCH amp SIGNAL D CONTENTS Section Page I INTRODUCTION 1 1 1 1 GENERAL DESCRIPTION 1 1 L2 PHYSICAL DESIGN l 1 1 3 GENERAL DESCRIPTION OF CIRCUITS 1 5 1 3 1 Transmitter Section 1 5 1 3 2 Receiver Section 1 5 1 3 3 Audio Amplifier 1 6 1 3 4 Regulated Power Supply 1 6 1 4 THEORY OF OPERATION 1 6 1 5 GENERAL SPECIFICATIONS 1 8 T II FCC LICENSING REQUIREMENTS 2 1 _ III INITIAL INSPECTION TESTS AND ADJUSTMENTS 3 1 3 1 INSPECTION 3 1 3 2 OPERATIONAL TESTS AND ADJUSTMENTS 3 1 3 2 1 General Remarks 3 1 3 2 2 Frequency Measurement 3 1 3 2 2 1 Test Equipment Or Equivalent Required 3 1 3 2 2 2 On Site Frequency Test Procedure 3 2 3 2 2 3 Shop Maintenance ON Procedure 3 3 3 2 3 Adjustment 3 4 3 2 3 1 Test Equipment Or 3 4 Equivalent Required 3 2 3 2 Procedure 3 4 IV APPLICATION INSTALLATION AND AIMING 4 1 4 1 BASIC APPLICATION CONFIGURATIONS 4 1 4 2 INSTALLATION 4 11 4 2 1 General Remarks 4 11 4 2 2 Cable Requirements SIG A SIG B TEST A TEST B 4 11 4 2 3 Check Signal 785 Hz 4 11 4 2 4 Power 117 VAC 4 11 p 4 2 5 Power Requirements 4 11 4 2 6 Electrical Interface 4 12 4 2 7 Final Checks 4 12 t 4 3 AIMING PROCEDURES 4 12 4 3 1 Horizontal Adjustment 4 12 4 3 2 Vertical Adjustment 4
19. ACCOMPLISHED BY LOOSING 4 MOUNTING PLATE BOLTS Unir une iT 5 AMED TO RAL RETIGHTED 80415 HORIZONTAL ADJUST MENT COL 5 21 0101 319 FoR 27 0 202 Z AXeancar ROTUSTMENT GF CAN SHED By LCOSEN ING 4 tuts 4 WASHERS ASem ues LOCATED ON MOUNTING FEET OF RADAR hub GR LONER ONE END UNIT UNTIL IT 45 MEO TO RAL VERTICAL ADTUSTIAENT 19 100 Nomnar RANGE 15 5 ios DRAWINGS 5 UN AAR TERMINAL STRIP Note A FrmnG PRavi0ED FOR 2 inca Bway START MOUNTING PLATE wann MOUNTING PLATE BALLAST OUNDATION WZ CONCRETE Foun THE OPERATION OF GISCUITR AND MENT REFH RAHTED HSREOM CAMMOY Bt FIMALLT CHECKED UNTIL CONNECTED 10 FOAM A COMPETE SYBTEM On SECTIOM OF BUCH A OUCH BYSTEM SECTION UNDERGO CIRCUIT CONTACT S LECTION iBANANDQU AWD BRAVICE OPENATIONI PRIOR TO PLACED INTO MEGULAA SIGNAL COMMUNICATIONS DIVISION COMP PHTURIPOn pa AMOUNT OF 31 1 degaes HoarzentaL 44 degrees AojUsT MENT 15 PERMITTED Gy THE AND THE EFFECTINE RAGE FoR VELOCITY
20. Resistor 680K Mfr AB 5 250 watt CB6845 Type Resistor 10K Mfr AB 5 250 watt CB1035 Type Resistor 51 ohm 1 4 watt 5 Resistor 27K 250 watt 5 Part Number J715029 0088 J715029 0061 J715029 0089 J715029 0070 J726133 J726031 J726150 0043 J726150 0044 J723621 J715027 J735159 J735301 J735137 J735399 J735053 J735407 J735065 6015 p 8 9 4 gt UNION SWITCH amp SIGNAL Item _ Legend 95 R20 100 R27 28 31 32 105 R30 110 R1 35 39 120 R36 125 R37 130 R26 135 C1 C3 140 C2 5 6 7 145 C4 21 150 C8 155 C9 160 C10 22 27 165 12 13 14 18 24 25 170 15 16 20 175 617523 180 C19 185 Q1 190 Q2 195 Fl 200 72 3 205 R33 34 275 C26 280 Cll 6015 p 8 10 Description Resistor 150K 1 4 watt 5 Resistor 22 ohm 1 4 watt 5 Resistor 47K 1 4 watt 5 Resistor 1 1 4 watt 5 Potentiometer 2K 20 5 watt Resistor 3 9K 1 4 watt 5 Resistor 51K 1 4 watt 5 Capacitor l Mfd Mfr TWC 5 Mylar 200 VDC Capacitor 30 pf Mfr CD 5 Mica 500 VDC Capacitor 250pf Elmehco 2 Mica 500VDC Capacitor 4 7 pf Mfr Srague or Mallory 10 35 VDC Capacitor 160 pf Capacitor 1Mfd Mfr TWC 5 200 VDC Mylar Capacitor 1 Mfd Capacitor 250 Mfd Mfr Sprague Tol 10 75 50 VDC Capacitor 001 Mfd Mfr Erie Tol 10 500 VDC Capacitor 3300 Mfd Mfr Erie Tol 10 75 25 VDC Transistor MJ 1000 Motor
21. 13 R fi t i i N IGURE i eo E By sG P R PCO 1 New Wire Jy m2 E I TR ye CREME ERE SOR p Apo REsiSTORS 5720851 Te RETARDER Boano 31 ae 1 4 i D 40 RF Uwr E PAIR pM TUI EET x GNO 4 gt Sia A 5 RFK SIGNAL Att lt I 2 16 8 Line Dawer 7 2 EARTH Sao GND To NEAREST AVAILABLE SOURCE SF EARTH 5 l GRD AT RETARDER TERMINAL BAARD 2 ORDERING REFERENCE E Nor vseo d 5 gt Gusucare 2 0 1 08 RADAR UNIT N4S1127 020 FOR BALLAST FouADfA Tib N i 120 FORMERLY N 51127 0207 FOR CONCRETE FOUNDATION G T i t NEAREST AVAILABLE SOURCE OF ROYAL Y 72035 I 7 NX12 O FoRMERLY RE RETARDER TERMINAL BOARD 2 1000 OHM WATT RESISTOR 4 t i RFK i PCB 5105 101 i gt Nov ost Driver PCB lt 1 Bok 204 i Disconnected CARD Fire 51042 0208 1 RETARDER 3 A A R 15 POWER SUPPLY 51033 26401 AS NEEDED NC 1 Terminar i 1 ee t t E CABLE E i E NE p
22. 29 6015 Connect the digital voltmeter common to 1 and input to 7 Is a reading of between 5 1 and 6 1 VDC present If no go to step 63 Mark this step number down Connect the test set up as shown in Figure 3 1 Set test set up approximately 6 inches in front of the DR 40 s horn antenna Perform procedure 3 2 2 2 steps 1 through 5 Is the Gunn Diode producing rf energy as determined by an indication on the power meter If yes go to step 21 If no go to step 69 Remove the digital voltmeter grom the previous position Connect the common to Faston 3 and input to Faston 1 is a 0 3 VDC 0 1 volt present If no go to step 23 Check track copper for open between Faston 1 and Rl1 R17 junction also between Faston 3 and ground buss Check also Cl R2 and Make repair to step 7 d 4 E STOP Move the voltmeter lead from Faston 1 to mixer diode on Doppler module Is 0 3 VDC 0 1 VDC present If no go to step 25 Check white conductor for open in coaxial cable between PC Board and Doppler module Make repair Go to step 7 STOP Is voltage either low or zero If no go to step 30 Turn power off Check zener mounted on Doppler module for short or changed value Is the zener test good If no go to step 29 Check mixer diode by substitution Turn power on The new diode will restore bias Go to step 28 Adjust the bias for 0 3 VDC Disconnect test equipment
23. CH 1 0 01 v Div Vert Attn Ch 2 Vert Mode 1 Coupling AC Horiz Time Base 2 milli sec Div Probe 10 1 Output at TP18 With 785 Hz Test Signal Scope Setting 2 3 Vert Attn CH 1 0 2 v Div Vert Attn Ch 2 Vert Mode CH 1 Coupling AC Horiz Time Base 0 5 milli sec Div Probe 10 1 UNION SWITCH amp SIGNAL D verification Renee 1 1 1 E AL NICE BNNNENESEENE ALA 1 6015 6 29 D b UNION SWITCH amp SIGNAL 6015 Operation Output at TP19 With 8 mph Tuning Fork Test Signal Scope Setting l 2 3 4 5 Vert Attn CH 41 0 5 v Div Vert Attn Ch 42 Vert Mode CH 1 Coupling AC Horiz Time Base 2 milli sec Div Probe 10 1 Output at TP19 With 785 Hz Test Signal Scope Setting Te 2 3 4 5 Vert Attn CH 1 0 01 v Div Vert Attn Ch 42 Vert Mode CH 1 Coupling Horiz Time Base 5 milli sec Div Probe 10 1 Output at TP20 Scope Setting 14 2 3 Horiz Vert Attn 2 v Div CH 1 Vert Attn Ch 2 Vert Mode 1 Coupling DC Time Base 20 micro sec Div Probe Direct Verification 21212111 1 2111 U L
24. FOR WIRING DR 20 to DR 40 Retrofit Procedures Wiring Modifications and 6015 p 10 5 6 NN 7 RETROFIT ot DR 40 Rapar Unit Basre 0 30 Tus 4 MENU eT RE CMM M a ECC MEM 40 Cunssis in DR 30 FoR New INSTALLATIONS Circuir D amp 40 7 14527 2 7 SEE N8 8 8 44 s BOX RKK 0 pP S 445148 0901 PANEL 2 6 55 Hera Ttt Srub 71 45 65 Ao4aigo Wine Le 9 7 1772 2 ms i Go 372086 Resistor WW Sto _ PE Ha PE 21 5 E 7 Spence 2 0 11 1 i t Jq 3 6 New Resisron Shown INSTALLED 2 9 3 CHECK FAIL PCB NASIOS4 6101 Remove gt UNION SWITCH amp SIGNAL he DRAO fe Udit WAS OESGNED TO BE THE DRIO UNITE THE PHYSICAL SIZE MOUNTING ARRANGEMENTS CABLE CONNEC Tis FORTHE DG 46 UNITS WERE CHOSEN So THAT V ULO MOUNTED IN AN EXISTING DQ 3O ENCLOSURE Mo PACKAGING ACTERATONS THE SIGNAL INPUTS OUTPUTS OF THE 04 60 UNIT ARE DIRECTLY COMPATIGLE WITH THE EXISTING WELAC VRIT Speco MEASUREMENT CONTROL EQUIPMENT WITH A MINOR MODIFICAT
25. lt 20 4 113 5 2 5 114 61 LEAR 86 015 7n BLACK 5 7 016 80 SHIELD 1 5 8 NOTES Indicates Twisted Pair 6015 p 6 14 DR 40 Wiring Diagrams Figure 6 6 6109 SI 9 1 white Gunn Diode unit 2 black Gunn Diode unit 3 shield Gunn Diode unit For complete call out of board components see section 8 3 starting on page 8 9 4 blue Tl 5 black Tl 6 red Tl 7 Shield J1 9 8 white J1 10 9 red fit M M 10 red T4 12 red yellow T4 11 white J1 13 UN451055 4201 Viewed from component side Call out order Faston No wire color destination Figure 6 7 DR 40 Faston Location Identification Q IWNDIS 8 H LIMS NOINN SS gt UNION SWITCH amp SIGNAL 6 3 5 2 Test Procedure 1 10 Connect voltmeter across AAR terminals 6 7 set 150 VAC scale Is voltage indicated on meter between 105 and 125 VAC If no go to step 72 Is a substitute DR 40 unit which is known to be in good operating condition available If no go to step 4 Replace the defective unit with a unit known to be operational Does the unit restore speed indication If no go to step 73 Secure and replace the cover This completes field expedient maintenance Shop maintenance of the inoperative unit starts at step 5 Set DR 40 Chassis on service bench Connect the test Set up as shown
26. 1 D UNION SWITCH amp SIGNAL 7 2 1 3 6015 p Removal of Schottky Mixer and Zener Diodes Remove Schottky by unsoldering its external connection and unscrewing the diode using a sharp wide blade screwdriver from the side of the transceiver module Remove Zener by unsoldering end wires Radar Signal Transformer T1 Remove harness clips from wire bundles which lead to Tl wire feed holes in chassis plate Using Figure 6 6 disconnect correct Faston attached wires on PC Board for Tl Using same figure unsolder correct Tl wires on underside of Tl Amphenol connector Remove Tl hold down screws on chassis plate and pull unit out making certain to help wires through hole grommets Amphenol Connector J1 Unsolder all wires to numbered terminals on underside of unit making certain they can be distinguished for correct reconnection Remove small nuts and screws and remove Jl from chassis Step Down Transformer T4 Remove wire harness clips from wire bundles feeding the transformer Using Figure 6 6 disconnect correct Faston attached wires for T4 at PC Board Cut T4 wire going to fuse assembly allowing sufficient wire on either side of the cut for resplicing Using Figure 6 6 unsolder T4 wire where it attaches to its numbered terminal on the underside of the Amphenol connector J1 Remove two screws which secure T4 to chassis and remove unit making certain to help wires through h
27. 12 V PERIODIC PREVENTIVE MAINTENANCE 5 6 Months 5 1 2 5 1 INSPECTION 5 1 2 5 2 CLEANING 5 1 2 VI IN DEPTH CIRCUIT DESCRIPTION AND TROUBLESHOOTING 6 1 1 Removal of Subassembly 6 1 6 1 ACCESS TO COMPONENTS 6 1 6 1 6 1 2 Board Access 6 1 1 Q D UNION SWITCH amp SIGNAL Contents Cont d Section VII 6 4 DETAIL DESIGN AND FUNCTIONAL DESCRIPTION 6 2 1 General Remarks 6 2 2 Power Supplies 6 2 3 Velocity Measurement Circuitry TROUBLESHOOTING PROCEDURES 6 3 1 Preliminary Checks 6 3 1 1 Physical Defects 6 3 1 2 Control Settings 6 3 1 3 Associated and Connecting Equipment 6 3 2 Isolating a Problem Circuit 6 3 3 Power Supply Problem 6 3 4 Checking Individual Components 6 3 4 1 Horn and Doppler Transceiver Module Components 2 Diodes Other Than RF 3 Transistors 4 Resistors 5 Transformers 6 Capacitors matic Circuit Trouble D Gg 4 Pp gt 6 3 5 1 General Remarks 6 3 5 2 Procedure VOLTAGES AND WAVEFORMS FOR TEST POINTS AND TERMINALS CORRECTIVE MAINTENANCE AND CALIBRATION 7 1 7 2 GENERAL REMARKS COMPONENT REMOVAL 7 2 1 Horn and Doppler Transceiver Module Components 7 2 2 1 Removal and Horn Module 7 2 1 2 Removal of Trans ceiver Module 7 2 1 3 Removal of Schottky Mixer and Zener Diodes Radar Signal Transformer 1 Amphenol Connector Jl Step Down Transformer T4 PC Board R PROCEDURES General Remarks Copper Track Repairs Circuit Boa
28. Ps 6015 p 4 5 6 UNION SWITCH amp SIGNAL gt a 90 PART E A RUP WV ss Lt FITTING PROVIDED FOR 2 HOSE CUSTOMER SUPPLY IA eR BET i OF SE Te K E OE A se 1 caen OREQUIVALENT FOR CONNECTING HOOK UP WIRES SEE gt 1 RADAR 54 40 Irlamiezio2 Tl 845828 54581 7 A SET C I FOUNDATION IN PLACE ON CENTER LINE OF 14111 14306403 C 01660761 TRACK AS INDICATED 5 4 sca exz A Hex cae Vg Lx x mex 1311 Ji 13 4 lslo475031_ lusum Yz T 2 OTT Josse nanara 1121711 4 luloso019 5 2 AAR TERMINAL STRIP 8 wAY 12 h 041766 IWSHR 4AS rLLocw 4 171548002 Mur V4 20H amp x Sr OF RAIL OF TRACK TOP OF TIE 7 gt 7 an TE 10x10 222222 s P ab ut _ N fs 22 pu tica 78 fy Loro ue 2 5 INTERNE IES 1 2 i f NOT RECOMMENDED v FOR NEW INSTALLATIONS h SIDE ELEVATION SEE 2451474 SHO
29. Reading 0 20 Dig Voltmeter Reading 1 30 Dig Voltmeter Reading 5 4 Dig Voltmeter Reading 5 1 Dig Voltmeter Reading 5 27 Dig Voltmeter Reading 23 96 6015 p 6 27 Q D UNION SWITCH amp SIGNAL 6015 Operation Output at TP15 Scope Setting l Vert Attn CH 1 0 2 volt Div 2 Vert Attn Ch 2 3 Vert Mode 1 Coupling DC 4 Horiz Time Base 2 micro sec Div 5 Probe Direct Voltage at TP16 GND at 1 Normal Operating Condition Voltage at 16 GND at TPl With 785 Hz Test Signal Output at TP17 With 8 mph Tuning Fork Signal Scope Setting 1 Vert Attn CH 1 0 05 v Div 2 Vert Attn Ch 2 a 3 Vert Mode 1 Coupling 4 Horiz Time Base 2 milli sec Div 5 Probe 10 1 p 6 28 Verification T EE i LOT JE AC Voltmeter Reading Low Level AC signal amplitude dependent on target return AC Voltmeter Reading 2 VAC Approx EN dI NE NT B LIU LU ALS a Operation Output at TP17 With 785 Hz Test Signal Scope Setting l 2 3 4 5 Vert Attn CH 1 O l v Div Vert Attn Ch 42 Vert Mode CH 1 Coupling AC Horiz Time Base 0 5 milli sec Div Probe 10 1 Output at TP18 With 8 mph Tuning Fork Signal Scope Setting 1 2 3 4 5 Vert Attn
30. and is half wave rectified by D20 and filtered by C12 and activates a NOR gate of IC7 The output without a calibration signal is at a high logic level and the presence of a calibration signal causes it to switch to a low logic level TP 14 This action opens the switch in the Doppler signal input path and causes the output of TP 13 to go to the high logic level activating the control input of the solid state switch at ICl Pin 5 and applying the 784 7 Hertz signal to the audio amplifier and line driver The calibration signal is then applied to the line and delivered to the monitoring point for velocity meter calibration 6015 p 6 8 q UNION SWITCH amp SIGNAL 6 3 TROUBLESHOOTING PROCEDURES 6 3 1 Preliminary Checks 6 3 1 1 Physical Defects Check the physical integrity of all components wires and connections via Section 5 1 If damage or deterioration is found proceed to Section VII and the appropriate corrective maintenance procedures 6 3 1 2 Control Settings Incorrect control settings can create indications of a problem that does not actually exist Check that all system controls are set properly Example Is power ON to the unit 6 3 1 3 Associated Connecting Equipment Make checks of the equipment being used in conjunction with the DR 40 including that associated with the power source Also check the physical integrity of all interconnecting cables 6 3 2 Isolating a Problem Circuit To isolate trouble t
31. emitter follower action The 5 6 volts supply is established at TP 7 by zener diode D10 whose output is filtered by Cl4 Regulation for the positive voltages is provided by IC 8 which is a Monolithic Voltage Regulator Type 723 used with external pass transistor Ql The voltage at TP 4 is adjustable between 8 to 12 volts by the setting of R 36 in order to provide the Gunn Diode voltage with the range of voltages marked on the Doppler Transceiver waveguide packages by the manufacturer The regulator output is filtered by C16 and zener diode D9 is used to establish the 5 6 VDC output which is again filtered by C13 Since the Gunn Diode is susceptible to voltage transients larger than the recommended supply voltage a zener diode D8 is used to prevent such transients from destroying the Gunn Diode The output of the positive regulator is fused at 1 1 2 ampheres by Fl 6015 6 3 5109 7 9 t ALIBRA lt e RECTIFIER z INPUT CONTROL DOPPLER AND BILATERAL SWITCH 5 AMPLIFIER INPUT CALIBRATION OR DOPPLER oorr BILATERAL SWITCH MIXER OUTPUT 9 RADAR POWER 8 12 vDC SUPPLY 10 VDC AS NOTED ON 56 GUNN DIODE voc Te 56 VDC DC COMMON Figure 6 3 DR 40 Radar Block Diagram SS 7IVNDIS 9 HOLIMS NOINN UNION SWITCH SIGNAL gt NOTES THESE WIRES CONTAINED IM ASBY 4 451128 1401 30PF 30PF
32. on the control input the switch is in the on state and whenever the control input is at a zero or a low logic level the switch is in the off state The printed circuit board also contains a COS MOS CD 4001AE Quad 2 Input NOR gate Two of the gates are used to form a multivibrator and the other two are used as logic level inverters The DR 40 also uses five style 777 Operational Amplifier Linear integrated circuits IC2 through IC6 are used as amplifiers and line driver IC2 and IC3 have amplification limiting which is performed by a Beam Lead Diode Array containing 6 matched diodes The Doppler Transceiver contains a mixer diode which functions as the receiver of the unit The diode requires forward bias amd this bias is developed by diverting a small amount of rf output energy from the Gunn Diode This is accomplished by a fixed ferrite circulator located in the waveguide unit and a 2 56 adjustment screw marked mixer on the waveguide assembly The screw adjustment can vary the dc voltage from a 0 2 to 0 4 volts dc at the mixer terminal The mixer output is fed to two parallel data processing circuit branches The first of these is the Doppler output and the second is the rfk output branch The Doppler circuit branch input contains a resistor capacitor network which loads and forms a high pass filter input to the first solid state switch of ICl The control input under normal velocity measurement conditions is at a high logi
33. wattage soldering iron may separate the wiring from the base material The following technique should be used to replace a component on a circuit board Most components can be replaced without removing the boards from the instrument 1 Grip the component lead with long nose pliers Touch the soldering iron to the lead at the solder connection Do not lay the iron directly on the board 2 When the solder begins to melt pull the lead out gently This should leave a clean hole in the board If not the hole can be cleaned by reheating the solder and placing a sharp object such as a toothpick into the hole to clean it out A vacuum type desoldering tool can also be used for this purpose 6015 p 7 3 4 UNION SWITCH amp SIGNAL 3 Bend the leads of the new component to fit the holes in the board If the component is replaced while the board is mounted in the instrument cut the leads so they will just protrude through the board Insert the leads into the holes in the board so the component is firmly seated against the board or as positioned originally If it does not seat properly heat the solder and gently press the component into place 4 Touch the iron to the connection and apply a small amount of solder to make a firm solder joint do not apply too much solder To protect heat sensitive components hold the lead between the component body and the solder joint with a pair of long nose pliers or other heat sink 5 C
34. 22 Flex PVC Black Marker Wire 1 to 33 Clamp Cable Scr 8 32 x 5 8 Rd Hd Washer 8 Flat Nut 48 32 Hex Stl Lug Solder Specific performance requirements should be made for these parts since operation may be affected or may nullify FCC Type Acceptance Part Number R451128 0601 N451128 0701 7708944 0401 J731446 N451055 4201 J731400 0004 N451039 0809 J702689 J713333 J710007 A774210 J751103 J050012 J047501 J047775 J507263 J050980 J047733 J050992 J047681 J525074 J047729 J480006 M073129 M451425 3402 M451108 5202 J490034 A045672 J723923 A045662 0000 J063646 0011 J700587 J052602 J047745 J048166 J731246 6015 p Items are special components manufactured or selected to meet outside substitutions 8 5 6 4 UNION SWITCH amp SIGNAL t MIXER Blas ADJUSTMENT VAT TC DE PARYS INCLUDED Seg DRY mas 18 Hear component waacoj 2 ORDERED 71731446 1 18 24 20 5 u 521 6 E 72727201 0 gt EP O 201 4 NOTE Denotes special components selected Hir bs D or manufactured by WABCO to meet T i as Tc performance requirements Contact 4 E bred m WABCO for replacement 129628 7 57 9
35. 30 oR OR DusreRoeF CASES THE CASE 15 MOUNTED IN THE TRACKWAY OA WAYSIDE AT pony WHERE VELOCITY MEASUREMENT 13 DESIRED THE RADIO FREQUENCY curPUT OF THE 40 13 DIRECTED PARALLEL TO THE RAILS ANO HORIZONTAL ADE LEVEL SOME SMALL q UNION SWITCH amp SIGNAL gt 25 WATTS RP ba ho ARE iSoLATER TAAUSFoamieR COMPLETE ELECTRICAL ISOLATION lt gt 3 al lt 5 o 121 al ais 7 CHARACTERISTIC s Qua Requirements ATO ours X 1040 y 0 LINE AT 1209 UNIT 100 to Hi7 OR ABOUT 42 ro V A Frequency Seam Minimum STABILITY SHALL OF 10 525 2 05 MRE Frequency Ooreur THE Band 40 500 be 0 550 8 Aff Type EMISSION with THE posta TRE ANTENNA ExceeD watts THE 2 D Ao RADIO FREQUENCY POWER OUTPUT 15 Bid ur KT ELY 400 to 725 MILLIWATTS Yee Hug 40 de Jove ASF to E WHOSE CUSTOMER TO SUPPLY Appeo pai ATE OF Hose HOOK UP CAME OPen ENO 4956 SCALEO With OR EQUIVALENT 1 Be TO RALA BELOW RAIL APPROPRIATE Apparition Dwa Z HoaizontaL AiminG hotustmenT OF Chu
36. 36 5 turns clockwise 2 3 Apply 117VAC 2 VAC to Amp 3 connector pins 5 and 12 4 Connect a digital voltmeter to 4 Set digital voltmeter to TP5 and common to 1 DC Volts and Auto Ranging Faston 3 5 Inspect operating voltage 5 marked on Gunn Diode Oscillator 6 Adjust R36 6 Operating voltage of Gunn Diode should be l volts DC Seal pot with inspectors laquer after adjusting 7 Allow DR 40 Radar Unit to 7 Should require 10 minutes stablize to operating temperature 8 Inspect frequency of Gunn Diode 8 Frequency should be 10 525 Oscillator as indicated on GHz l MHz HP532B frequency meter 9 Adjust FREQ ADJ screw if 9 When the frequency is 10 525 required GHz 1 0 MHz seal with inspectors laquer 6015 p 3 3 Q gt UNION SWITCH amp SIGNAL HP 430C X 487B 2 DR 50 RADAR TUNING FORK gt WAVEGUIDE AXIS MUST PARALLEL Figure 3 2 Frequency Measuring Test Shop Set Up 3 2 3 RFK Adjustment 3 2 3 1 Test Equipment Or Equivalent Required Fluke 8120A 01 Digital Voltmeter 3 2 3 2 Procedure Ls Connect voltmeter negative lead to the anode and the positive lead to the CATHODE of the 1N759A Zener Diode located on the Gunn Diode transceiver module 2 Apply operating power to the DR 40 unit 3 Allow a 10 minute temperature stabilization period The detector bias shall indicate 4 VDC on the digital voltmeter assuming little no
37. 56315 M451118 1501 M223608 J047818 M029103 M029101 M210527 J075510 0128 J075510 0154 J075510 0180 J075510 0197 J075510 0214 J075510 0225 J075510 0236 J075510 0245 N451128 1401 N262807 N700588 M451128 1204 J047714 J052091 J052202 J047775 J048002 J052531 J521081 J047745 J047681 J048166 J525011 M398923 R380487 M451128 1206 J078147 J048016 J048217 J050019 M435757 6051 p 8 1 2 4 UNION SWITCH amp SIGNAL gt 2 Pc5 24 Ya LG 2 PCs 7 16 V Cc 4 LJ ALL ELASTIC STOP MUTS MUST BE APPLIED INVERTED 6015 p 8 3 4 Figure 8 1 DR 40 Main Assembly Parts Location Ss gt Q UNION SWITCH amp SIGNAL 8 2 CHASSIS N451128 0801 Standard Reference Figure 8 2 Item No 25 26 27 28 29 30 31 32 33 34 35 36 Description Plate Mtg Bracket PCS Mtg Antenna X Band Horn Doppler Module PCB Radar Tranf Step Down T4 Tranf Radar Signal Tl Conn Amphenol J1 Post Fuse 342014 Fuse 1 Amp 250V F2 Tubing 1 2 Shrink Grommet Scr 1 4 20 x 1 2 Hex Cap Washer 1 4 S Plate Washer 1 4 S Lock Scr 1 4 20 x 5 8 S Scr 10 32 x 1 2 Bing S Washer 10 S Lock Scr 8 32 x 1 2 Bind S Washer 8 S Lock Scr 4 40 x 3 8 Rd S Wash 4 Shpr LK 1204 Nut 4 40 Hex S Washer 10 Flat Plate Name Plate Name Rivet 1 8 POP Cable 20 2 Cond Sh Term Faston 250 Wire
38. 72015 24 0013 EARN Gut 04510 54 4601 3 TAG 2015 74 0074 SPARE 8 3 PIS POVER Pray Requires 2 TAS 1591A 00715 516 Common 451033 2601 3 TAG 15824 00 TEST A TAG 2015874 0011 5 3 15924 09018 NX TAG JOd4582 OO74 TEST 8 PLACEO IN CLOTH PARTS BAG 3 5003 TIED TO CHASSIS RADAR APPLICATION CUT THIS GARONO WIRE CINGULATE SEE FIGURE seme 27 Moe ii zr 3 52 7 eo Casu 08 70 z amp rt Ft Same Composte 4 THESE New WIRE Rus SHOULO AF 10 V iN CABLE 3 005 Zin DR 4O TO 06 20 Retaorit THE OPERATION OF THE CINCUIT amp AND KQUIP MENT FiKALLY CHECKED UNTIL CONNECTED TOFURM A COMPLETE SYSTEM OR SECTION OF SUCH A SYSTEM SYGTEM OR SECTION MUST X9HOZAGO CIRCUIT CONTACT BELECTION QBREAKDOWM AND IOPERATION TESTS PRIOR YG BEING PLACED INTO REGULAR Equiement Kao Keeucanion Notts i5 DENS SIGNAL amp COMMUNICATIONS DIVISION KEVDKGHOUSE AIR COMPANY PUTIAURGR PA 13018 Figure 10 3 References WABCO SIGNAL amp COMMUNICATIONS DIVISION WESTINGHOUSE AIR BAAKE COMPANY FITYSEURCH PA 13118
39. 777 i gt 1 aK 516 6 gt 2 CABLE SAG iei Q 680 TEST IHeUT 1O TEST 13 awaseo gXu1 5 NZ wu 12 CHASSIS 7 RADAR UNIT MOUNA BRACKETS ENO OF 08 40 Case PAAT 4451128 1401 4 5942 E3 159u8 SM 4015 EQuiement Cuaracter istics 5 M Mepucation Notes SH a4 as FON WIRING n Figure 4 5 DR 40 Characteristics 6015 p 4 9 10 Q UNION SWITCH amp SIGNAL D 4 2 INSTALLATION 4 2 1 General Remarks For optimum operation and maximum sensitivity avoid installing the DR 40 Radar unit near strong broadcast station towers neon signs heavy power lines or in general any areas which have noisy broadcast radio reception It should be understood however that even when such noise conditions exist and a target comes into range of the DR 40 Radar unit the output indications will be the true measured velocity of the target and the environments noise will in no way be additive to the true target velocity Using the selected application method see Section 3 2 reposition and refashion ties and excavate ballast as required to allow correct installation of the radar on its mounting base to keep within clearance parameters Make certain that the modified secti
40. Application Between Rails Ballast Foundation DR 40 Radar Application Between Rails Concrete Foundation DR 40 Radar Application Between Rails Single Pylon Ballast Foundation DR 40 Radar Application Notes and Characteristics DR 40 Radar Horizontal Aiming Adjustments DR 40 Vertical Aiming Adjustments DR 40 Disassembly Diagram Relocation of Horn and Gunn Diode for Service Access DR 40 Radar Block Diagram DR 40 Radar Schematic Diagram DR 40 Radar Test Set Up DR 40 Wiring Diagram DR 40 Faston Location Identification DR 40 Radar Main Assembly Parts Locations DR 40 Radar Chassis Mounted Component Locations DR 40 Radar PC Board Component Locations DR 40 Gunn Diode Chassis Mounted in DR 30 Enclosure DR 5 10 Radar Replacement With DR 40 Procedures Wiring Modifications and References DR 20 to DR 40 Retrofit Procedures Wiring Modifications and References DR 30 to DR 40 Retrofit Procedures Wiring Modifications and References LIST OF TABLES Application Guide Power Supply Tolerances lv 8 3 4 8 7 8 8 11 10 2 10 3 4 2 10 5 6 10 7 8 UNION SWITCH amp SIGNAL SECTION I INTRODUCTION 1 1 GENERAL DESCRIPTION The DR 40 Solid State Radar Unit is designed to detect and guage railroad car velocity by means of the Doppler effect When the transmitted signal from the DR 40 strikes and is reflected back from the target a change in frequency occurs The return signal is detected and compared to
41. CTING HOOK UP WIRES SEE DWG D451474 SH O 5 5 20 aepeu op ud HOLIMS d TRACK OF 4 3 r ES 4 Y Y IN INTERMEDIATE RETRACED IN FROM DG66052 54 14 Figure 4 2 A FITTING PROVIDED FOR 2 INCH HOSE CUSTOMER To SUPPLY APPROPRIATE LENGTH OF HOSE TO PROTECT HOOK UP CABLE END OF HOSE To BE SEALED WITH DUXSEAL OR EQUIVALENT FOR CONNECTING HOOK UP WIRES SEE DWG D451474 SH 02 00906 5 K S o 451414 0901 DR 40 et WESTINGHOUSE BRAKE UNION SWITCH b SIGNAL PITTSBURGH FENRRSYLVANIA 19400 B ANGULAR Application of the DR 40 Between the Rails Ballast Foundation FINISHED MLESS aes EL ern ito p ah 4 i R UNION SWITCH SIGNAL T s amm e Hi m 3 gt RADAR De 40 203 22 22 22 Rane 0 coven 10 sex Hanger TEM semen eta 2 ES Scg 4 20x 19x Sn B c 1 E H 45 StL Lock g Ble
42. Hewlett Packard Model 430C or equivalent 6015 p 3 1 gt b UNION SWITCH amp SIGNAL 3 2 2 2 ON SITE FREQUENCY TEST PROCEDURE NOTE The 2 56 Set Screw located on the Gunn Diode is pre set at the factory and should not be adjusted in this part of the test 1 Apply operating voltage to the rf unit under test 2 Insert 1N23B crystal in detector mount and attach standard gain horn antenna see Figure 3 1 below Use coaxial cable such as RG 58 to connect the Simpson voltmeter to the circuit E d BARREL OF FREQUENCY METER MUST BE IN THE HORIZONTAL POSITION SHOWN WHEN MAKING MEASUREMENTS DETECTOR MOUNT FREQUENCY METER STANDARD GAIN HORN Figure 3 1 Frequency Measuring Test Portable Set Up 6015 p 3 2 4 UNION SWITCH SIGNAL D 3 Place horn antenna several feet in front of radar unit Set frequency meter for 10 525 MHz 4 Turn adjustable detector mount until a maximum indication is seen on the voltmeter d c scale 5 Adjust frequency meter for a maximum dip on the voltmeter Read the frequency directly from the frequency meter This test only indicates the operating frequency and that the Gunn Unit is functioning It does not check the amplifier operation If the DR 40 Radar unit does not fall within the specified frequency tolerance proceed to Section VI 3 2 2 3 SHOP MAINTENANCE PROCEEDURE OPERATION VERIFICATION l Arrange a test setup as per l Fig 3 2 2 Adjust R
43. ION OF THE RFK CONNECTION IN THE RACKS THE MAIN BETWEEN THE UNITS 1S iW THE SUPPLY CONNECTIONS A SpEUAL PowER SUPPLY S Not REQUIRED By THE 56 40 FOLLOWING 15 STEP STEP PRockOURE FoR RETROFMNG OR 40 UNITS IN EXISTING 00 30 INSTALLATIONS DR 40 to DR 30 RE evaperr DN stave ions 1 Remove AND INSULAE Wires MARKED FAILURE 8 C Insrho Carson 7 110851 55 TERMINALS 20 8 OM SIGNAL TRANSFORMER 5 LOCATED ON TRANS FORMER Paner 5 IN RACK AN3 Connect THE CENTER LEAD OF LENGTH SINGLE SHIELDED CABLE A45183 Oo2Y BLACK 4427 SHIELOED oR tQuu PIN 7 OF THE RETROFIT SIGNAL TRANS FORMERS DRESS THE SHIELO S OF THESE CAGiE S TO INSUATE THEM AS ARE Mor COHNECTEO AT THE TRANSFORMER END ALON We FAIL Pc N451054 GIo1 THAT 15 0560 MONITOR THE RETROFITIED RADAR LOCATION S REMOVE THE SHIELDED WIRE CONNECTED TO PIN AL AND GRouNQ 8955 AT RACK LOCATION 5 Whee THE 5 PAEMIOUSLY CONNECTED O THE RETROFIT RADAR SIGNAL TRANS FORMER S Pin 44 if RADAR ri ERA SHIELD CARO FILE GROUND 8055 ON THE SSociATEO Nea 6 4 06 30 Gacor
44. NYT 4 20 Hex StL LI __ 14141211 15 1214 5 ARR TERMINAL STRIP 8 x CYLINDER TIE iQx 10x 10 APPLICATION OF RADAR OS DE RAILS FOR GENERAL INFORMATION SEE D451414 54 01 SCALE H C Getz 4 10 75 APPLICATION AND CHARACTERISTIC DWes cm Aad 6 IS FOR DR 40 RADAR NOTED Se e VA UNION SWITCH amp SIGNAL DIVISION Weetinghonse Pirnebargh Ps 1424 ULA Set DA51474 6015 4 3 4 lt TOP OF TIE OF TRACK ETWEES TES gt n PART 059 2 c gs 36507 396 JN Figure 4 3 of Nr E H CYLINDER TIE Ox1O Application 4 71 2 4 A PROVIDED IOR 2 INCH Hoot CUSTOMER 7O SUPPLY APPROPRIATE t t HOSE TO PROTECT CABLE OPEN END CF HOSE To BE SEALED WITH PUWVASEAL EQUIVALENT FOR CONNECTING HOOK UP WIRES SEE DWG 451474 SH 02 I i 5 4 SIDE ELEVATICN TTUPTUTTTPTUTTT iw451474 0801 RADAR DR 40 4 53127 lo202 5 435651 84528 ARASAN sce V4 ___ pee 69095655
45. O UNION SWITCH SIGNAL DIVISION 58 25 z 2293 Meat rtt Figure 10 4 References Vy WEBTINGNGUGE BRAKE COMPANY PITESTI 15210 DR 32 and DR 40 Retrofit Procedures Wiring Modifications and 6015 p 10 7 8
46. P APPLICATION OF RADAR INSIDE 5 Fog GENERAL APPLICATION INFORMATION SEE 5451414 5 01 i ___________ T a 7 D O 5 23 34 oc reet scade APP HCAT ION gt 8 DwWGS FOR VELAC DR 40 RADAR bet ara RAC rona GEN Owe NEXT ASSY PLODUCED M PART D G66052 9H1 40650483 75 6 Pa erst wa mule 10071706 UM POCO 199 tas Puma 08 41 CURES 19 m 5 ELSE perl N 1 mL s Jet eee WABCO UNION SWITCH SIGNAL Division ov inert un led f q Westeghews Ar Brahe Pa DE RA 46 gt 3217 peg DIM ens D 451474 07 5 Par edi Figure 4 4 Application of DR 40 Radar Between the Rails Ballast Foundation 6015 p 4 7 8 Gigun S Grace REQUIREMENTS X Sys A 515 8 Tesr Test 6 Caste Sme nEeD MANMUM iodb C OC Loop REINE GOO 447 K Gua QereRence
47. TAILED CIRCUIT DESIGN AND FUNCTIONAL DESCRIPTION 6 2 1 General Remarks Block and complete circuit schematic diagrams of the DR 40 Radar unit are shown in Figures 6 3 and 6 4 respectively Refer to Figure 9 2 for placement of chassis components and 9 3 for printed circuit board components partrs called out on pages preceding these figures All electrical inputs and outputs are terminated on a 16 pin Amphenol male connector mounted on the subassembly chassis 6 2 2 Power Supplies Voltages and 5 6 VDC to O 5V Plus 10 5 VDC Adjustable 8 to 12 VDC Minus 9 0 VDC 5 volts The primary source of power for the DR 40 Doppler Radar Unit is 117 60 hz which is applied to terminals 21 5 and 21 12 and to feed the primary winding of step down transformer T 4 The transformer primary is fused F2 at one ampere The Secondary winding is center tapped and the center tap is tied to the chassis and serves as chassis and signal ground TP 1 The secondary ac voltage of T4 is rectified by D12 to D15 and filtered by C19 and C20 to produce unregulated voltages of approximately minus 17 volts and plus 16 volts dc at TP 2 and TP 3 respectively Regulation for the negative voltages is provided by the zener reference voltage of 011 and the operation of pass transistor Q2 This reference voltage of approximately 10 5 volts is filtered by C18 and C23 and is applied to the base transistor Q2 and produces 9 0 4 5 volts at TP 6 by
48. and restore the DR 40 to operational status a Replace the defective zener diode Check that mixer diode bias is restored with zener replacement STOP p 6 18 30 31 32 33 34 35 36 37 38 UNION SWITCH amp SIGNAL D Turn bias adjustment screw Does bias adjustment give a reading of 0 3 VDC 1V If no go to step 32 Make setting Carefully tighten locking nut not to change setting and seal with inspector s lacquer Recheck rfk voltage to confirm operation of rfk section of the radar STOP Turn off power to DR 40 unit Check the 1000 ohm resistor and the zener diode mounted on the Doppler module for an open or changed value Check also for shorted inner conductors of cabling to Doppler module Make repair and go to step 75 STOP Connect the scope common to TPl and the probe to TP22 Is an approximately llV p p signal present as shown in operation AA on page 6 31 32 If yes go to step 34 If no go to step 41 Disconnect scope from previous position Connect digital voltmeter to TP13 and TPl Is a high level 5 1 VDC approx present If go to step 37 Disconnect digital voltmeter lead from TP13 and connect it to TPl4 Is a low level 3 96 VDC present If no go to step 38 Turn power off Check R3 R4 R5 C22 and ICl Replace defective component turn power on and go to step 42 STOP Disconnect the digital voltmeter lead from TP13 and conn
49. c level and therefore the Doppler signal is passed without alteration to the first of two identical ac amplifiers made up of IC2 and IC3 The low signal level and low frequency gain of these amplifiers is set by the ratio of R8 to R78 or 11 to R10 which is approximately 130 per stage diode networks formed by the CA3039 packages perform a gain limiting function by conducting on both positive and negative half cycles when the signal output of IC2 and IC3 is sufficient to forward bias the three matched diodes effectively in series These diodes when conducting shunt R8 or 11 and reduce the gain of each stage The capacitors C21 and C4 set the high frequency gain roll off The output of IC2 and IC3 is limited to about 2 2 volts peak to peak under normal Doppler signal input 6015 p 6 7 D UNION SWITCH amp SIGNAL The linear integrated circuit amplifier IC4 serves as the line driver It has a gain of approximately two and its output contains back to back zener diodes Dl and D2 for transients suppression The output level at TP 19 is about 5 volts peak to peak R15 R16 and C26 serve as loading and a low pass output filter Transformer Tl couples the Doppler output to the line which is terminated at the monitoring location by the velocity meter The second circuit branch in parallel with the mixer output is the rfk branch The rfk branch s function is to deliver to the monitoring circuitry a DC voltage level that is
50. component is installed in place of an old one If any tags are missing the technician should install new tags carrying the correct Faston or Amphenol number on the wires before disconnecting them in preparation for removal of the component If the wires are accidentally disoriented after disconnection carefully follow the wiring diagram on Figure 6 6 to retrace their correct locations 7 2 COMPONENT REMOVAL 7 2 1 Horn and Doppler Transceiver Module Components NOTE The transceiver module may be substituted without removing the horn antenna from the chassis 7 2 1 1 Removal of Horn and Module 1 Unsolder connections to the various external components of the module and to the internally located Schottky Mixer Diode making certain that the wires can be distinguished for correct reconnection 2 Remove four screws on underside of chassis which hold horn and module with spacer posts to chassis 3 Lift horn and module assembly away from chassis 7 2 1 2 Removal of Transceiver Module 1 Unsolder connections to the various external components of the module and to the Schottky Mixer Diode making certain the wires can be distinguished for correct reconnection 2 Remove the four screws which hold the module on the horn antenna these screws are on the antenna side of the module and pull the module away from the antenna Make certain to secure the o ring gasket for reuse when the horn and antenna are reassembled 6015 p 7
51. components such as resistors capacitors etc may be ordered from the manufacturer or outside sources If ordered outside take care to note the exact description value tolerance rating etc of the replacement to make sure that it matches the original component When ordering these parts it is important to remember that the physical size and shape of the component may affect its performance in the instrument particularly at high frequencies All replacement parts should be direct replacements unless it is specifically known that a different component will not adversely affect system performance 9 3 ORDERING When ordering a replacement component supply the following information 1 RF unit type DR 40 2 Unit serial number 3 Description of the part including circuit number for electrical parts 4 Manufacturer s part number 6015 p 9 1 2 4 UNION SWITCH 4 SIGNAL D SECTION X Replacement of DR 5 amp DR 40 Radars with DR 40 Retrofit of DR 40 Into DR 20 amp DR 30 Radar Systems The DR 40 Radar is capable of being substituted in place of DR 5 and DR 10 Radar systems in classification yards equipped with the older systems It is also capable of being retrofitted into DR 20 and DR 30 Radar assemblies Consult the three following general information sheets Figures 10 2 10 3 and 10 4 for all pertinent information regarding the above System modifications Figure 10 1 shows a DR 40 Gunn Diode chassis
52. cy signals through the circuit 6 3 4 6 Capacitors A leaky or shorted capacitor can best be detected by checking resistance with an ohmmeter on the highest scale Do not exceed the voltage rating for the capacitor The resistance reading should be high after the initial charge of the capacitor An open cspacitor can best be detected with a cspacitance meter or checking whether the capacitor passes ac signals 6015 p 6 11 D UNION SWITCH amp SIGNAL 6 3 5 Systematic Circuit Troubleshooting 6 3 5 1 General Remarks The following diagnostic routine consists of a series of consecutive subroutines which must be followed in the indicated order The individual steps describe actions to be taken with the test equipment ask for verification of test results and recommend where to look for faults based on unsatisfactory test results Some also recommend how to deal with faults In general it may be assumed that if a step yields a yes answer to a particular question or gives no special go to instructions then the routine may proceed to the next consecutive step When the word STOP is reached a subroutine has been completed The proceeding would then continue onto the next subroutine if no fault or variance in test results is found Note that go to instructions for no answers to test results may take the procedure over to steps in other subroutines The technician should be careful to observe variations in this general approach a
53. d defective component and go to step 75 If no go to step 74 Place the horn frequency meter thermistor mount test set up aside Connect a dc voltmeter positive lead to Faston 2 and the negative lead to Faston 3 is a voltage of between 8 5 and 11 VDC present If no go to step 71 Decrease supply voltage to Gunn Diode by adjusting potentiometer R36 this is done so as not to apply excessive voltage to a new Gunn Diode TURN POWER TO UNIT OFF Substitute another Transceiver unity J731446 which is known to be in working condition Turn power to unit ON Adjust R36 to supply a voltage which is within 0 1 VDC of the voltage marked on the new module DR 40 unit should now be operational Check frequency and power using test procedure outlined in Sections 3 2 2 3 STOP Check for open in track copper on PC Board either between TP5 and Faston 2 or an open between ground buss and Faston 3 Make repair and go to step 75 STOP Check DR 40 s power switch on the Power Distribution Panel Find where the break or open is located and take corrective action Does this restore operation Can be confirmed with tuning fork test described in step 3 Go to step 2 STOP 6015 p 6 23 D UNION SWITCH amp SIGNAL 73 74 75 Defect is not in DR 40 chassis Check all interconnecting cabling from equipment room rack to radar cases AAR terminal strip Check also interconnecting cable between radar case s AAR terminal strip and
54. e Unit Weight Subplate Unit Operating Temperature Range E 4 28 L x 11 W x 12 7 8 H 15 3 8 L x 7 3 8 W x 7 5 8 H 44 lb s housing included 10 4 lbs 400C to 70 C 409F to 160 F ELECTRICAL RF OUTPUT FCC Data Operating Frequency Frequency Stability Spurious Emission Power Output rf Nominal Range Type of Emission ELECTRICAL SIGNAL VOLTAGES Doppler Audio rfk Check Signal Required ELECTRICAL INPUT SUPPLY Voltage Frequency Power Consumption 6015 p 1 8 10 525 GHz MHz 0 2 of Assigned Frequency No Emission Greater Than 44 db Over Entire Frequency Range Except At Assigned Frequency 125 mW Maximum 50 mW Minimum 150 Feet Continuous Wave l4V p p Limited into 500 ohms Greater than 1 0 VDC 2V Mixed Bias into 500 ohms 95 to 125 VAC 60 Hz 12 to 14 Watts boe UNION SWITCH amp SIGNAL SECTION II FCC LICENSING REQUIREMENTS Because the DR 40 Radar Unit is capable of emitting a signal into the atmosphere it may not be operated or maintained without the applicable FCC License This includes the station license and the individual operator s license Any adjustments affecting power or frequency must be made by or under the direct supervision of a person holding a valid Second Class or higher commercial radio telephone operator license Application for new or modified station license can be obtained by writing the nearest FCC fi
55. eck all associated interconnecting wiring on board Make repair and go to step 75 STOP Remove scope probe from TP17 and connect it to 16 Is minimum 10V p p signal at 785 Hz present If no go to step 50 Turn power to unit off Check R6 R7 R8 C2 C3 C21 DAl and IC2 plus all associated interconnecting wiring Make repair Go to step 75 6015 p 6 20 STOP E lt F 49 50 51 52 53 54 55 56 57 UNION SWITCH amp SIGNAL D Turn power to unit off Check IC3 IC4 C3 C4 C5 R9 R10 Rll and DA2 Check all interconnecting and associated wiring Make repair and go to step 75 STOP Turn power off Check Cl Rl R2 and Check all associated track Make repair and go to step 75 STOP Disconnect the digital voltmeter from the PC Board Connect the oscilloscope probe to TP15 and the ground lead to TPl Set vertical on scope to 0 2V Div and horiz sweep to 2 0 microseconds div Does the scope pattern displayed approximate that shown in operation P on page 6 28 x If no go to step 55 Remove scope probe from TP15 and connect it to TP20 Is the 5 2V p p signal present as shown in operation y on page 6 30 If no go to step 54 Turn power off Defect lies in circuitry between TP20 and TP21 Check R27 R28 R41 R42 D4 DS and D16 through 219 C24 C25 C27 and T2 Check track copper side board Sections 6 3 and 7 3 give guidelines on compo
56. ect it to TPl4 IS a low level present 3 96 VDC on the voltmeter If no go to step 39 IC7 or the connections to IC7 is defective Confirm which by testing Make repair and go to step 42 STOP 6015 p 6 19 Q D UNION SWITCH amp SIGNAL 39 40 4l 42 43 44 45 46 47 48 Check 5 6 VDC Supply Voltage should be 5 1 to 6 1 VDC Turn power off and check also IC7 R26 R30 12 and D20 Make repair Turn power on and go to step 42 Check all voltages against Table II Check ground buss for open Are all voltages within tolerances If yes go to step 67 If no go to step 62 STOP Check 5 6 VDC Supply Voltage should be 5 1 to 6 1 VDC Turn power off and check also TP3 R31 R32 D6 D7 and 020 Make repair Turn power and go to step 42 STOP Now connect the scope probe to TP19 Is a 17V p p signal present similar to that shown in operation X on page 6 30 If no go to step 44 Turn power off Check Dl D2 R15 R16 C26 and Tl Check all wiring in proximity of this circuit Make repair Go to step 75 STOP Remove scope probe from 19 and connect it to TP17 Isa 2 8V p p signal present similar to that shown in operation T on page 6 29 If no go to step 47 Remove the scope probe from TP17 and connect it to TP18 Is a 7V p p signal present as shown in operation V on page 6 29 If no go to step 49 Turn power to unit off Check R12 R13 R14 C6 and IC4 Ch
57. eld engineering office Request the following forms freom Engineering In Charge at the office FCC Form 400 Application for Radio Station Authorization in the Safety and Special Radio Services FCC Form 400 10 Instructions for Completion of FCC Form 400 NOTE WABCO DR 40 Radar has been FCC Type accepted COMMISSION FIELD ENGINEERING OFFICES ALABAMA HAWAII NEW YORK Mobile 36002 Honolulu 08808 Buffalo 14203 P O Box 1021 New York 10014 ALASKA ILLINOIS OREGON Anchorage 99501 Chicago 60604 Portland 97204 P O Box 644 CALIFORNIA LOUISIANA PENNSYLVANIA San Diego 92101 New Orleans 70130 Philadelphia 19106 San Francisco 94111 Los Angeles 90012 COLORADO MARYLAND PUERTO RICO Denver 80202 Baltimore 21201 San Juan 00903 P O Box 2967 DISTRICT OF MASSACHUSETTS TEXAS COLUMBIA 20554 Boston 02109 Deaumont 77701 Dallas 75202 Houston 77002 FLORIDA MICHIGAN VIRGINIA Miami 33130 Detroit 48226 Norfolk 23502 33602 GEORGIA MISSOURI WASHINGTON Atlanta 30303 Kansas City 64106 Seattle 98104 Savannah 31402 P O Bocx 8004 November 1971 or later revision 6015 p 2 1 2 SS UNION SWITCH amp SIGNAL SECTION III INITIAL INSPECTION TESTS AND ADJUSTMENTS 2 2 INSPECTION Upon removal of the DR 40 from its packing carton examine the housing for any impact damage or loosened fastener hardware Then unlatch the cover and examine the chassis for any indication of internal impact damage loosened or complete
58. et area is a rfk voltage of approximately 3 7 VDC indicated on meter If no go to step 15 Check wiring run from 21 1 to Tl center tap Check secondary for an open Make repair Return to step 7 to confirm unit is operational STOP Check wiring run from 21 2 to transformer Tl for an open Check secondary of Tl for an open Make repair Return to step 7 to confirm operation STOP Disconnect the digital voltmeter Activste one of the tuning forks and place it 3 inches in front on the DR 40 s horn antenna Is a minimum 10 signal present the oscilloscope If yes go to step 16 If no go to step 10 Place the tuning fork aside Connect the digital voltmeter s input lead to Faston 7 on DR 40 PC Board and the common lead to Test Point 21 TP21 Does the voltmeter read 3 7 VDC approx If no go to step 51 Turn power to unit off Check wiring and connections between TP21 and transformer Tl center tap Check also continuity of wiring from Faston 7 through the cable shield to AAR terminal 3 if unit is being serviced in the field Make necessary repair Go to step 75 STOP Connect the audio signal generator set for 6V p p at 785 Hz to Faston 8 and Faston ll Does the scope show an approximately 7 2V p p signal as in operation BB on page 6 31 32 If no go to step 40 6015 p 6 17 gt b UNION SWITCH amp SIGNAL 19 20 21 22 23 24 25 26 27 28
59. f all external wiring to the 8 way AAR terminal block interconnection to the DR 40 subassembly part number N451128 0801 is provided by means of a cable assembly part number N451128 1401 which is provided with the unit See Figure 6 6 for specific electrical wiring assignments to the DR 40 Radar unit 4 2 7 Final Checks a Inspect all wiring tags and check that they are on the correct AAR terminals on the DR 40 unit and on the equipment room rack b Check for loose AAR terminals nuts which would result in intermittent operation c Inspect for stray hardware which might short between AAR terminals d Check to see if cable plug connectors are secure and properly seated both in the DR 40 unit and in the equipment room 4 3 AIMING PROCEDURES 4 3 1 Horizontal Adjustment The horizontal adjustment range for the N451127 0201 unit is 6 degrees Adjustment range for the N451127 0202 unit is 1 degrees To adjust horizontally l Loosen the four mounting plate bolts 2 Rotate unit until parallel with rail 3 Retighten mounting bolts 4 3 2 Vertical Adjustment The vertical adjustment range for all units is 1 5 degrees To adjust vertically l Loosen the four elastic stop nuts or mounting feet of the radar 2 Raise or lower one end of the unit until it is aimed parallel to the rail 3 Regighten elastic stop nuts 6015 p 4 12 3 Q UNION SWITCH amp SIGNAL D
60. in Figure 6 5 Go to step 6 Apply power and allow approximately 30 min for warmup stabilization Go to step 7 Connect the digital voltmeter s common lead to J1 9 and the input lead to 71 1 Aim the DR 40 into a maximum unobstructed distance With no movement of uniy and no movement in target area is a rfk storage of approximately 3 7 VDC indicated on meter If no go to step 12 Disconnect the voltmeter lead from Jl 1 and place it on Jl 2 Again with no movement of unit nor movement within target area is a rfk voltage of approximately 3 7 VDC indicated on meter If no go to step 14 Disconnect the voltmeter from the unit Connect the audio signal generator to 41 10 and J1 13 set output to 785 Hz 6V peak to peak Connect the oscilloscope to 91 1 and 1 2 Is a 7 2V p p signal approx present as shown in operation BB on page 6 31 32 If no go to step 33 Disconnect audio frequency signal generator Activate the 440 Hz tuning fork and place it 3 inches in front of DR 40 s antenna Is the 7 2 approx volt p p signal present If no go to step 74 6015 p 6 16 11 12 13 14 15 16 17 18 UNION SWITCH amp SIGNAL UNIT IS OPERATIONAL Disconnect all test equipment secure the DR 40 so it may be placed back in operation when required STOP Disconnect the voltmeter lead from 21 1 and place it on 21 2 Again with no movement of unit nor movement within the targ
61. indicative of normal radar transceiver operation The signal level at 10 is approximately 0 3 volts dc 5 is a amplifier with a gain of about 59 so the signal level at 11 is about 1 5 VDC Two NOR gates of IC7 are connected to form a multivibrator whose output at TP 12 is a 10 V p p squarewave at about 11 KHz This signal is applied to the control input of the solid state switch ICl which alternately activates deactivates the switch The output at TP 15 is essentially the same level applied to the solid state switch input but chopped at the multivibrator rate IC6 is an ac amplifier with a gain of about seven Its output contains transient suppression diodes D4 and D5 and is transformer coupled to a diode bridge dc voltage developed by the bridge rectifier 016 17 18 19 and filter C24 is applied between the shield wire of the velocity output cable and the center tap of transformer Tl The dc velocity is recovered at the monitoring point by connection to the center tap of the transformer at the receiving end of the line and the shield Upon installation it is necessary to calibrate the velocity meter at the monitoring point obtain and refer to FCC Rules and Regulations Manual Part 90 This is done by applying a calibration signal of 784 7 Hertz to the calibration line and transformer T3 This input contains transient suppression D6 and D7 and the signal is fed to both the input of the solid state switch at pin 4
62. ing on a concrete foundation and N451127 0203 for mounting on two cast iron foundations see Section IV for details The subplate assembly forms the composite electronics package The subplate is composed of three primary sub assemblies Antenna Doppler module assembly radar P C board and mounting plate Details of these items are shown in Section VIII Parts List 6015 p 1 1 UNION SWITCH amp SIGNAL Figure 1 1 6015 p 1 2 DR 40 Weatherproof Enclosure UNION SWITCH amp SIGNAL D Figure 1 2 DR 40 Radar Subplate Assembly N451128 0801 6015 p 1 3 UNION SWITCH amp SIGNAL Figure 1 3 DR 40 Subplate Assembly Mounted in DR 40 Enclosure 6015 p 1 4 4 UNION SWITCH amp SIGNAL 1 3 GENERAL DESCRIPTION OF CIRCUITS The WABCO DR 40 unit is a complete self contained solid state zal doppler radar transceiver It operates on a frequency of 10 525 GIGA HERTZ 10 525 000 000 Hz with a nominal power output of 75 milliwatts Power requirements for all active circuitry in the unit are provided by regulated power supplies which operate from 117 VAC 60 Hz power lines Following is a block diagram of the DR 40 unit SCHOTTKY POWER GUNN DIODE DIODE SUPPLY TRANSMITTER RECEIVER ANTENNA TRANSMITTED TO TARGET REFLECTED SIGNAL s 147 VAC RFK DOPPLER SIGNAL CARRIER TO VELOCITY METER RFK INDICATION CHECK SIGNAL AUDIO AMPLIFIER Fig
63. ir Com PLETELY OPERATIONAL nor s RADAR APPLICATION CUT THIS GROUND 31 8 f I lt WIRE AND INSULATE SEE RE veure B 4 31 4 F hoo D ME v To n 4 Rerenence A STANDARD _ Nasze osoz Gereo ere Chassis 3 m a VRI SYSTEM 8 D F451128 SH 8 7 R 30 1 CHANGE From READ uu AM MEE 300 Qr N 330 57 81N 3 15 gt PS UE CHE REP SPARE p 5 ve L u 15 EARTH GND 3 0658 Ser 14 a 6 SPARE 3 31 14 2 3 Pst 16 COMMON Prue 3 5 TESTA TNTEACONNECTING CABLE i viae i CONNECTOR RFK SeAR amp M 4390651 N 380658 SA 8 WEE TERMINALS ARMA MN 30 E ET Agema DRAO to QeraoriT FIG THE OPLAATION OF CIRCUITS ANO REFERENCES pues cr 22222223 PME Lee 22 545244 9 lt 028 er utat er aer men GERUCE GOLS peenaa tonto N 2218 429250552 gr e Ano CATION 3 8 lt 2 8 TO INTO ACOULAA i 21275 3 258 s ZZ 741 WABC
64. lip the excess lead that protrudes through the board 6 Clean the area around the solder connection with a flux remover solvent Be careful not to remove information printed on the board 7 4 REASSEMBLY PROCEDURES Reassembly of the DR 40 generally consists of reversing the steps described in Sections 6 1 removal of chassis from enclosure and 7 3 removal of components from chassis As noted in the previous section the technician should closely observe the identities and exact locations of the wires that are attached to PC Board Fastons the Amphenol connector and the Horn Gunn Diode unit Wires that were cut for disassembly purposes such as those going to the fuse assembly must be spliced soldered and wrapped with electrical insulating tape or similar insulating material Make certain that no wire cuttings or other debris remains on the chassis when it is put back into the enclosure 7 5 FINAL TEST AND CALIBRATION 7 5 1 General Remarks The following procedure must be completed following any type of component replacemnt or cirucit repair performed on the DR 40 Radar It assures that the unit will operate at the required radio frequency after reinstalltion Use the general circuit schematic on page 6 5 6 Figure 6 4 the test set up on page 6 13 Figure 6 5 and the wiring diagram on page 6 14 Figure 6 6 to help carry out the procedure 28 D 6015 p 7 4 UNION SWITCH amp SIGNAL D 76522 Test Equi
65. ly separated components damaged wires and broken or loosened electrical connections The radar must not be placed into service until any such problems have been remedied If the damage is not reparable in the field or the repair not authorized the radar unit should be returned to the manufacturer as shipped Any unit being stored or reshipped should be kept at temperatures between 40 F 40 C and 160 F 70 C Consult Section VII of this manual for repair information 3 2 OPERATIONAL TESTS AND ADJUSTMENTS NOTE Prior to being placed in service each rf unit must be checked to determine that it is maintaining the proper frequency 10 525 MHz This frequency is the same for all rf units although each install ation is assigned a different call sign The fre quency must also be rechecked at regular intervals refer to Part 93 of FCC Rules and Regulations for the applicable information 3 2 1 General Remarks This test of the DR 40 Radar unit requires removal of the sub assembly chassis from the protective enclosure Go to section 6 1 1 for the required steps 3 2 2 Frequency Measurement 3 2 2 1 Test Equipment Or Equivalent Required Frequency Meter Hewlett Packard Model X 532B Analyzer Simpson Model 260 Standard gain horn Narda Model 640 Adjustable detector mount Hewlett Packard Model X 485B Crystal 1N23BN or 1N23C Thermister Mount Hewlett Packard Model X 487B Associated Hardware for Assembly Power Meter
66. movement occurs in the target gt area This voltage can be varied by unlocking the 2 56 nut and adjusting screw located on the Gunn Diode transceiver module Make certain to retighten the locknut after adjustment NOTE ANY MOTION OR OBSTRUCTION IN FRONT OF THE ANTENNA WILL ALTER THE INDICATED VALUE AND RESULT IN AN INACCURATE CALIBRATION Q UNION SWITCH amp SIGNAL D SECTION IV APPLICATION INSTALLATION AND AIMING 4 1 BASIC APPLICATION CONFIGURATIONS The DR 40 Radar Unit may be installed adjacent to or between the rails Install the DR 40 Radar as indicated by the proper application drawing shown in the table below Table I Application Guide Figure Drawing Application Foundation Number D451474 Sheet X451474 0601 Outside of Rails Ballast X451474 0701 Between the Rails Ballast X451474 0801 Between the Rails Concrete 451474 0901 Between the Rails Ballast Wiring Configuration Two cast iron pylon bases used 6015 p 4 1 T09 Line 9 Prepared from drawing D451474 06 Rev 3 AAR Terminal Strip 8 way 5 TIE TO Drews SHON 4 174 SIDE ELEVATION LS D crum om IS U PROVIDED FOR 2 HOSE CUSTOMER SUPOLY LENGTH OF HOSE TO PROTECT HOOR UP CABLE OPEN END OF HOSE TO BE SEALED WITH DUXSEAL OR EQUIVALENT FOR CONNE
67. mp cloth to remove foreign materials Do not use any corrosive chemicals which may be potentially destructive to the housing or rf window 3 Reconnect ac power and replace top cover 6015 5 1 2 q UNION SWITCH amp SIGNAL gt SECTION VI IN DEPTH CIRCUIT DESCREIPTION AND TROUBLESHOOTING WARNING TO AVOID PERSONAL INJURY AC POWER TO THE RADAR UNIT MUST BE DISCONNECTED BEFORE TAKING ANY STEPS TO PULL THE UNIT FROM ITS MOUNTING IN THE CLASSIFICATION YARD 6 1 ACCESS TO COMPONENTS 6 1 1 Removal of Subassembly 1 Remove topside cover from enclosure 2 Disconnect Jl connector as located in Figure 6 1 3 Using a 3 8 socket drive tool remove 3 retaining nuts on base plate also indicated in Figure 6 1 4 Carefully lift the subassembly chassis out of the enclosure 6 1 2 P C Board Access 1 Remove four hex head cap screws which attach horn and 4 Doppler transceiver module to subassembly chassis 2 Disconnect wiring harness dress from chassis 3 Rotate horn Doppler transceiver module 909 away from P C board side as indicated in Figure 6 2 3 8 SUBASSEMBLY RETAINERS Figure 6 1 DR 40 Disassembly Diagram 6015 p 6 1 gt UNION SWITCH amp SIGNAL PRINTED CIRCUIT BOARD Figure 6 2 PRINTED CIRCUIT BOARD GUNN DIODE UNIT Figure 6 2 Relocation of Horn and Gunn Diode For Service Access 6015 p 6 2 Q UNION SWITCH amp SIGNAL gt 6 2 DE
68. mplifier section 1 3 3 Audio Amplifier The audio amplifier receives either the Doppler signal or a precise 784 7 Hz check frequency from a frequency standard Either of these signals is amplified limited and are outputted to the velocity meter The amplifier passes a Doppler signal when a check signal is not present When a check signal is present the Doppler Signal is shunted and the check signal passes This check Signal is used to assure that the audio amplifier is operating properly In addition to the audio amplifier the printed circuit board also contains an rfk voltage controlled oscillator check amplifier This circuit provifes a negative dc output when the Gunn Diode is providing microwave energy to sufficiently bias the Schottky detector This signal assures that the Gunn Diode and detector diode are operating properly 1 3 4 Regulated Power Supply The regulated power supply provides all the necessary operating voltages to the various electronic components and is normally operated from the commercial 117 volt A C 60 Hz power lines It should be noted that all input and output signals to the DR 40 radar unit are isolated via transformers providing complete electrical isolation 1 4 THEORY OF OPERATION Velocity measurements which are made using the Doppler principle rely on a shift in frequency that occurs when a radio signal bounces off a moving target The frequency difference between the incident and reflected
69. nd to follow individual step instructions carefully A useful aid in this procedure is to mark down the number of completed steps so that procedure is followed in the proper order Immediately following the numbered test procedures are the correct voltages and waveforms that should be obtained from test points and terminals as they are individually analyzed in the procedures The three immediately following figures 6 5 6 6 and 6 7 are provided for orientation with the test set up chassis wiring and Faston locations Of course use the general schematic on page 6 5 6 for troubleshooting procedures as well NOTE Test Point 1 is used as a common for voltage measurements unless noted otherwise Go on to page 6 16 for initiation of test procedures 6015 p 6 12 GT09 cT 9 POWER METER HP 430 C DR 40 WAVEGUIDE AXIS MUST BE PARALLEL 1 SIG A B SWITCH OR QUICK DISCONNECT TEST 17 VAC INPUT Figure 6 5 DR 40 Radar Test Set Up HOLIMS NOINN SS UNION SWITCH amp SIGNAL 1 t 4 amp rim prep 42 214 AE AES 20015 GUNN sa e sg i pL 90 56 d EAS ArI TE AS CONNECTOR Jl INTERNAL VIEW TERMINAL BLACK AN 5 1 19 10 x CLEAR 42 CONNECTOR 011 31 bod 43 21 BLACK 5 112
70. nent testing and replacement When repair is made go to step 75 5 Turn power off Check IC6 11 R25 and R26 Check all associated copper and make repair Then go to step 75 STOP Disconnect the oscilloscope from the previous position Now connect the digital voltmeter to TP10 common to ground Is the voltage on meter 0 25 VDC 0 05V If no go to step 59 Disconnect the voltmeter lead from 10 and reconnect it to TPll Does the meter indicate 1 4 VDC 0 1V If no go to step 60 Disconnect the voltmeter Connect the scope to 12 Is a 10V p p squarewave at approximately ll KHz present on Scope as shown in operation K on page 6 27 If no go to step 61 6015 p 6 21 gt UNION SWITCH amp SIGNAL 58 59 eo 61 62 63 64 65 66 Turn power to unit off Check IC6 C10 R22 R23 R24 and all track copper on board in this area Make repair and go to Step 75 STOP Turn power to unit off Check track copper of board for open between 10 and 1 17 junction Check also from Faston 3 and ground buss Make repair then go to step 75 STOP Turn power to unit off Check IC5 R17 R18 R19 and C7 Check all track connections in the area of this circuitry Go to step 75 STOP Turn power to unit off Check ICl IC7 R20 R21 and R22 Make repair Go to step 75 STOP Are any of the supply voltages within the tolerance values
71. o a specific circuit note the symptom The symptom often identifies the particular circuit in which the trouble is located Example If speed measurement fails but check reveals that the rfk voltage is present on Sig A and Sig B then the problem can be traced to the Doppler portion of the circuitry After the trouble has been isolated to a particular circuit check the Faston connectors on the circuit board for correct locations see Figure 6 7 Faston connectors may be used for circuit isolation 6 3 3 Power Supply Problem Incorrect operation of all circuits often indicates trouble on the supply Check first for the correct voltages of the individual supplies If correct voltages are indicated then another component is causing the problem which also can appear as a power supply problem and thereby affect all other circuits Refer to the following table for power supplies tolerances If tests reveal a misadjusted supply go to section 7 5 p 7 4 for adjustment procedures 6 3 4 Checking Individual Components NOTE Checks described in the following sections for soldered components are best conducted by disconnecting one end of the component so as to isolate it from surrounding circuitry 6015 p 6 9 Q UNION SWITCH amp SIGNAL Table II Power Supply Tolerances Voltmeter Positive Voltmeter Lead TP4 Unfused and TP5 Fused Power Supply 10 5 Volt Adjustable 8 VDC to 12 VDC m
72. ola Transistor 2N3644 Silicon PNP VcB 45 Mfr Fairchild Clip fuse Transformer Resistor 220 ohms 1 4 watt 5 Capacitor 22 Mfd 10 l00VDC Capacitor 5 P F 5000 VDC Tol P P Mfr Cornell Dub Part Number J735040 2735059 4735035 7730031 J620850 0028 J735066 J735067 J706813 2702815 2700604 2706422 2706935 2706827 2706387 7709058 9706242 9709010 9731427 9731283 9576794 N386389 J735071 J706858 J706931 hoc dd ST09 21 11 8 Do 4 015 ore os Orn PRO 660 2 Li LI R12 R13 RH 814 Di C19 UN451055 4201 Figure 8 3 Dr 40 Radar P C Board Component Locations Q TWNOIS SS E E 4 UNION SWITCH amp SIGNAL SECTION IX PARTS REPLACEMENT AND ORDERING 9 1 RF COMPONENTS All components of the Doppler Transceiver Module marked with an asterisk on the list on parts list page 8 5 6 must be ordered directly from the manufacturer no substitutions from outside sources may be made These have been specially selected and designed to meet specific performance requirements to keep the radar within FCC authorization limits A substitute component not obtained from the manufacturer could possibly change performance values to the point where the radar no longer operates within these limits 9 2 STANDARD ELECTRICAL COMPONENTS Standard electrical
73. ole grommets PC Board Disconnect all Faston connectors making certain wires can be distinguished for correct reconnection Remove retaining screws on bottom side opposite component side and remove PC Board from chassis back 7 2 4 UNION SWITCH amp SIGNAL gt 7 3 REPAIR PROCEDURES 7 3 1 General Remarks WARNING MAKE CERTAIN POWER TO UNIT IS DISCONNECTED BEFORE MAKING SOLDER REPAIRS Repairs on DR 40 components are limited to resoldering of broken soldered connections and breaks in PC board copper track No attempt should be made to disassemble or conduct repairs on any individual chassis transceiver module or PC Board component As noted in Section 6 faulty components are replaced with new units for fault correction purposes 7 3 2 Copper Track Repairs 1 Use a 35 to 40 watt grounded pencil type soldering iron and 60 40 rosin core solder for repairs 2 Clean section of track determined to have open 3 Deposit a uniform bead of solder along the track but do not leave the iron touching so long that excess heat causes the track to buckle and come off the board 4 Remove any excess which could cause a short with an adjacent track or component connection 7 3 3 Circuit Board Repairs Use ordinary 60 40 rosin core solder and a 35 to 40 watt grounded pencil type soldering iron on the circuit boards The tip of the iron should be clean and properly tinned for best heat transfer to the solder joint A higher
74. on of track as a whole maintains standards for tie spacing and ballast support 4 2 2 Cable Requirements SIG SIG B TEST A TEST a Maximum signal attenuation shall not exceed 10 db at 1000 Hz b Maximum dc loop resistance 500 ohms C Cable twisted pair shielded 4 2 3 Check Signal 785 Hz a Maximum signal attenuation shall not exceed 10 db at 1000 Hz b Total dc loop resistance shall not exceed 500 ohms c Cable twisted pair shielded 4 2 4 Power 117 VAC a Cable must meet all local electrical code requirements b Capable of providing a minimum of 25 watts at each AAR Terminal Strip 4 2 5 Power Requirements Each DR 40 Radar unit contains all the regulated electronically filtered power supplies essential to the operation of its various electronic circuits These power supplies are energized via an internal isolation stepdown transformer which is intended to operate from the commercial power lines The input power requirements for each DR 40 unit are 95 to 125 volts 60 Hertz and 1 to 117 ampheres Each DR 40 unit does not require more than 12 to 14 watts operating power 5 6015 4 11 UNION SWITCH amp SIGNAL 4 2 6 Electrical Interface All extertnal electrical connections are accomplished by means of a standard 8 way AAR terminal block This terminal block is located within the DR 40 Radar enclosure as shown in Figure 8 1 on page 8 3 4 After connection o
75. pment Or Equivalent Required Electronic Counter ATEC 5A35 Oscilloscope Tektronix 454 Oscilloscope Probe Tektronix P6028 30 pfd J043495 Audio Oscillator Hewlett Packard 204C Digital Voltmeter Fluke 8120A 01 Thermistor Mount Hewlett Packard X 487B Power Meter Hewlett Packard 430 C Frequency Meter Hewlett Packard HP 5326 Standard Horn Antenna Narda 640 Tuning Fork 440 Hz Middle A Approx 14 M P H 7 5 3 Supplementary Hardware 1 Matching Transformer Meissner TR5 J731015 2 Resistors 1000 ohm 1K 1 2 Watt 5 Carbon 2720882 7 5 4 Procedure Operation Remarks 1 Arrange a test set up as Figure 6 5 2 Apply 117 VAC 2 VAC to Amphenol Pins 5 and 12 3 Connect Digital Volt 3 Digital voltmeter set to meter to TP5 and common DC volts and Auto Ranging to TPl Faston 3 4 Inspect operating voltage marked Gunn Diode Oscillator 5 Adjust R36 5 Operating voltage of Gunn Diode 1 volts dc Seal pot with inspectors lacquer after adjusting 6 Allow equipment to 6 Room temperature 689F to stabilize for 30 minutes 770F 20 C 25 C 5 min 7 Inspect frequency of Gunn 7 Frequency shall be 10 525 Diode Oscillator as indi Ghz 1 MHz cated on the Frequency Meter 7A Adjust FREQ ADJ Screw 7A 10 525 Ghz 1 0 MHz and if required seal with inspectors lacquer 6015 p 7 5 gt UNION SWITCH amp SIGNAL 9A 10 11 12
76. rd Repairs EMBLY PROCEDURES TEST AND CALIBRATION General Remarks Test Equipment Or Equivalent Required J J Hj J J J tt n N Ur gt WP li E w D OY OY OY ON UO Ue ae AO oe adr 6 10 6 11 6 11 6 11 6 11 6 11 6 12 6 12 6 16 I gt FH e J J I I I Ph O C CJ N I 5 H Q UNION SWITCH amp SIGNAL D Contents Cont d Section Page 7 5 3 Supplementary Hardware 7 5 7 5 4 Procedure 7 5 VIII PARTS LIST 8 1 8 1 DR 40 MAIN ASSEMBLY 8 1 8 2 CHASSIS 8 5 6 8 3 PC BOARD 8 9 IX PARTS REPLACEMENT AND ORDERING 9 1 9 1 RF 5 9 1 9 2 STANDARD ELECTRICAL COMPONENTS 9 1 9 3 ORDERING 9 1 REPLACEMENT OF DR 5 5 DR 10 WITH DR 40 RADAR 10 1 RETROFIT OF DR 40 INTO DR 20 amp DR 30 iii D v UNION SWITCH amp SIGNAL Figure ua E P EIE F4 t P Q i UU N F 15 N FS OY WHR TAOS w 00 1 I I I gt LIST OF ILLUSTRATIONS DR 40 Weatherproof Enclosure DR 40 Subplate Assembly N451128 2101 DR 40 Subplate Assembly Mounted In Enclosure DR 40 Basic Block Diagram Doppler Effect Incident and Reflected Signal Frequency Measuring Test Portable Set Up Frequency Measuring Test Shop Set Up DR 40 Radar Application Outside of Rails Ballast Foundation DR 40 Radar
77. retrofitted into a DR 30 protective enclosure WARNING MAKE CERTAIN THAT AC POWER TO THE OLD RADAR UNITS DR 5 DR 10 DR 20 or DR 30 HAS BEEN DISCONNECTED BEFORE BEGINNING ANY DISMANTLING OP EQUIPMENT MAKE CERTAIN THAT AC POWER REMAINS OFF UNTIL THE DR 40 INSTALLATION HAS BEEN COMPLETED IF POWER REMAINS ON DURING DR 40 RETROFIT WORK PERSONAL INJURY MAY RESULT 6015 p 10 1 109 GUT uuu WABCO meo am p w s wa RADAR UNIT NATA IR 40 Len Figure 10 1 DR 40 Retrofit in DR 30 x T 5 8 9 HOLIMS UNION SWITCH amp SIGNAL E RSION S FicunE 7 PONE 1 DISCONNECT THESE WIRES CONVERS Instructs NS TO Gnsucare ones l E QO Howh ISCONNECT wWiRE i YAR A RETARDER TERMINAL hace SUCRE AS Saon FROM RETARDER TERMINAL C RUNE TURO EN jc 2 Moo RESISTORS 1729871 TO TRANSFORMER Ti ON RETARDER 300 V DC VELOCITY METER PANEL AS SHOWN iN FiGuRECO SEE NOTE BELow p r er 3 ADD LINE DRIYVERCNYSIOSH 410 AS SHOWN 14 Ficun e OG Axrso gt CARD FILE AMD 15 VOLT SUPPLY AS NEEDED E 2 NIU 5 ADD NEW WIRE TO TERM MC AETARDER VELOCITY METER PANEL AS SHouN gt gt Kisu ATE uo IN Eoo RE
78. signal is proportional to the speed of the moving object If the frequency of the reflected wave is higher than that of the incident wave the object is approaching If the frequency of the reflected wave is lower the object is receding However either condition produces the same difference frequency at any given speed p 1 6 4 UNION SWITCH SIGNAL D RECEIVER F DOPPLER F F Figure 1 5 Doppler Effect Incident and Reflected Signal The DR 40 Doppler Radar unit employs a continuous wave transmitter The return energy is detected by a Schottky detector diode Reflected signals from a stationary object produce no difference frequency in the mixer diode whereas a moving target produces the Doppler frequency difference between transmitted and reflected signals The following is the mathematical formula for this phenomenon 2V Fd Ft Ft C V C WHERE Fd Doppler frequency in Hz second Ft Transmitted frequency in Hz second V Target radial velocity in M P H C Speed of propagation in M P H 6 714 x 108 In the case of DR 40 Radar units operating at 10 525 GHz the following calculation can be made FREQUENCY OF DOPPLER PER MILE PER HOUR 9 _ 40 525 x 1 1 4 1 86 x 107 3 6 x 107 1 6015 1 7 D UNION SWITCH amp SIGNAL 1 5 GENERAL SPECIFICATIONS PHYSICAL Dimensions Complete Unit Dimensions Subplate Unit Weight Complet
79. sistance between terminals Use an ohmmeter with an internal source between 800 millivolts and 3 volts A normal diode will show a high resistance in one instance and a relatively lower resistance when the meter leads are reversed Faulty diodes will show high resistance in both directions open or low resistance in both directions shorted 6 3 4 3 Transistors Transistors suspected of having a defect are best tested by substituting an identical one for it which is known to be operating properly then carrying out operational tests However it is possible that a circuit fault at another location caused damage to the original transistor and that the same damage may be inflicted on the replacement Carry out other components and wiring tests if this latter situation is suspected or if the replacement transistor incurs the same apparent problem as the original If substitute transistors are not available use a dynamic tester such as a Tektronix 575 or equivalent Refer to Section VII for replacement techniques 6 3 4 4 Resistors Check resistors with an ohmmeter using Parts List to obtain the correct tolerances for the resistors in question Replace only those resistors with test values which vary widely with the intended value 6 3 4 5 Transformers Transformers are checked for an open or short partial short in the windings Use an ohmmeter to check continuity for an open For shorts check waveform response by passing high frequen
80. the 16 female connector Make repair STOP Turn power to unit off Check Cl and R2 Check all associated track copper and make repair Go to step 75 STOP When repair is made disconnect all test equipment and restore all hareware on the DR 40 unit so it can be placed back in service when needed VOLTAGES AND WAVEFORMS FOR TEST POINTS AND TERMINALS NOTE TPl used as common ground for all measurements unless noted otherwise Oscilloscope is set for NORMAL Horizontal Time Base Mode AUTOMATIC Horizontal Time Base Trigger NON STORE Display For all displays shown which follow 6015 p 6 24 Operation Output at Test Point 2 TP2 Scope Setting 1 2 3 Vert Attn CH 1 0 02v Div Vert Attn Ch 2 Vert Mode CH 1 Coupling AC Horiz Time Base 5 millisec Div Probe 10 1 Output at Test Point 3 TP3 Scope Setting l 2 3 Vert Attn CH 1 0 02v Div Vert Attn Ch 2 Vert Mode 1 Coupling Horiz Time Base 5 millisec Div Probe 10 1 Output at Test Point 4 TP4 Scope Setting 1 2 2 Vert Attn CH 1 10 milli volt Div Vert Attn Ch 2 Vert Mode 1 Coupling AC Horiz Time Base 5 millisec Div Probe Direct UNION SWITCH amp SIGNAL Verification Eu ELI ea nee NE WATERAIR AN A V vo
81. the original radiated frequency The degree of shift in frequency 31 4 Hz mile per hour is detected amplified and limited The output signal frequency directly proportional to the target s speed can then be put into and translated to a velocity meter The DR 40 utilizes complete solid state electronics The conventional klystron rf source is replaced by a solid state Gunn Diode Power supply amplifiers and check circuitry for the DR 40 are contained on a PCB mounted to a chassis The chassis in turn is contained in an all weather housing designed to be mounted and aimed at an appropriate yard location for scanning of cars The unit is internally shock mounted for vibration protection in the typical classification yard environment 1 2 PHYSICAL DESIGN The DR 40 Radar consists of two main assemblies a weatherproof enclosure and a subplate assembly These are shown in Figures 1 1 1 2 and 1 3 Cabling is terminated at an AAR terminal strip inside the DR 40 enclosure A plug connector cable connects the AAR terminal strip to the DR 40 subplate assembly The DR 40 Radar enclosure is constructed of steel sheeting to resist damage by dragging equipment A non metallic plate forms rf window which allows the microwave to pass through while shielding the electronics from dirt and the elements The DR 40 Radar is available complete with any of three mounting bases N451127 0201 for mounting on a cast iron foundation and N451127 0202 for mount
82. ure 1 4 DR 40 Basic Block Diagram The DR 40 Radar consists of four sections transmitter receiver audio amplifier and regulated power supply 1 3 1 Transmitter Section The transmitter section contains a Gunn Diode Microwave oscillator which oscillates with sufficient rf power output to provide a one step conversion from dc to microwave energy therby eliminating complex circuitry The diode opertates through a negative resistance caused by transfer of electrons 24 from high mobility band to low mobility conduction band The signal is fed to the antenna through a waveguide A ferrite circulator located in the waveguide deflects a small a amount of transmitted energy which is used to bias the mixer diode of the receiver The deflected signal serves as a reference frequency in the receiver 153 2 Receiver Station The receiver section is located in the portion of waveguide that joins the Gunn Diode microwave source to the antenna The detector is a Schottky Barrier Mixer semi conductor junction which is hermetically sealed in a ceramic case 6015 1 5 D UNION SWITCH amp SIGNAL 6015 In operation microwave energy transmitted from the antenna is reflected from the target and enters the receiver waveguide by way of a common antenna This return signal is mixed with the reference signal providing a Doppler frequency equal to 31 4 Hz per M P H The resulting Doppler audio frequency is applied to the audio a
83. v xev ve p gt UNION SWITCH amp SIGNAL 6015 Operation Voltage at TP5 GND at TP1 Normal Operating Condition Output at TP6 Scope Setting 1 Vert Attn CH 1 10 milli volt Div 2 Vert Attn Ch 42 3 Vert Mode 1 Coupling AC 4 Horiz Time Base 5 millisec Div 5 Probe Direct Voltage at TP7 GND at 1 Normal Operating Condition Voltage at TP8 GND at 1 Normal Operating Condition Output at TP9 Scope Setting 1 Vert Attn CH 1 0 01 volt Div 2 Vert Attn Ch 42 3 Vert Mode CH 1 Coupling AC 4 Horiz Time Base 0 2 millisec Div 5 Probe Direct p 6 26 Verification Dig Voltmeter Reading 10 503 Dig Voltmeter Reading 5 514 Dig Voltmeter Reading 5 298 Operation Voltage at TP10 GND at TP1 Normal Operating Condition Voltage at 11 GND at 1 Normal Operating Condition Output at TP12 Scope Setting l Vert Attn CH 41 5 volt Div 2 Vert Attn Ch 2 3 Vert Mode 1 Coupling AC 4 Horiz Time Base 20 micro sec Div 5 Probe Direct Voltage at TP13 GND at 1 Normal Operating Condition Voltage at 13 GND at 1 With 785 Hz Test Signal Voltage at 14 GND at 1 Normal Operating Condition Voltage at 14 GND at 1 With 785 Hz Test Signal UNION SWITCH amp SIGNAL Verification Dig Voltmeter

1 - Ansaldo STS

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