Vital Plug-In AC Vane Relay PV-250
Contents
1. 1 1 1 3 1 Electrical Specifications oia aida 1 2 1 3 2 Mechanical Specifications RN RR LA REN RR EROR RR Redde 1 2 2 INSTALLATION oi LEER sec des 2 1 MMEC DI LECCE 2 1 2 1 1 Care imi 2 2 1 24 2 String Remoyval dicta 2 1 2 2 Mounting 2 1 23 Relay Indexing dla 2 1 2 4 Receptacle Contact 2 2 2 4 7 Old style Base Only cir erint ds 2 2 2 4 2 Improved One Piece Base 004 0 0 0 0 2 2 2 4 3 Installing Wires Receptacle Contact 2 4 2 5 Relay Insertion niic cte reet erst ere ce aan reo Le RAE erue LE cruda ee LR ee 2 5 3 FIELD d 5uccc 3 1 IM UNO UCI UE 3 1 3 2 Periodic Performance Test ett trt ee rta eet iq ind ea 3 1 Clean e a eee 3 1 3 2 2 Service 3 1 A SHOP MAINTENANCE nerunt eh nete hr nt epa sa e kao nonae ka nta Eae a Ra Da CER nb a RR no a ER ax uua nbn 4 1 44 m2. Ze 8v LL AOL 6 Ze A9v LV IIT 8 A Sv LY 000017 9 LM QL SL 000 Figure 5 1 Assembly Drawings for PV 250 Part No N322555 002 5 3 SM 4574B January 1999 Ansaldo STS Parts Lists and Diagrams 5 2 Parts List For Vane N380678 Used on Relay Pv 250 with Part No N322555 002 See Figure 5 2 Table 5 2 Vane Assembly Parts List ITEM SATS USA PART Vane Clips Buffer Rivets 14 x 5 16 Rd Ph Bz Washer Rivets 11 x 5 16 Rd Ph Bz Crank L H Oper Arm Crank R H Oper Arm Rivets 14 x 13 16 Rd Ph Bz Figure 5 2 Parts Location for Vane Assembly N380678 5 4 SM 4574B January 1999 Ansaldo STS Parts Lists and Diagrams 5 3 Parts List for Contact Blocks with the Following PC Numbers N376779 Ref A and N376450 Ref B Used on Relay PV 250 N322555 002 See Figure 5 3 ASTS USA PART ITEM DESCRIPTION NUMBER REFERENCE SM 4574B January 1999 PW Ansaldo STS Parts Lists and Diagrams Qu 7 NOILOAS C Ne m 6 2 mcm m p n
3. 4 1 42 Cleaning Inspection etd ex era den des 4 1 4 2 1 Inspection for Loose Counterweights and Trunnion Screw Locknuts in AC Vane Relays N322555004 and 322555804 4 1 4 2 2 Cleaning Relay 4 2 43 Shock Indicator unir t eere et tee ovd de s ET Ex Lege 4 4 4 4 Check Out Procedure Performance 4 4 4 5 Repairs and 4 5 4 5 1 Recommended Tools and Test Equipment 4 5 4 5 2 4 5 453 4 6 4 5 4 General Parts Replacement 00000000 4 8 4 6 AUS MENS Ebr et bec p sae 4 10 46 1 Recommended Tools et tt e aote e car bett ah Oe X RA 4 10 SM 4574B January 1999 iii Ansaldo STS Table of Contents 4 0 2 Contact ACJUSIMONUS ii otra creatio dp i o ERROR DR 4 10 4 6 3 Counterweight 4 11 4 7 O 4 13 4 7 1 Recommended Test
4. Va NOILO3S Ju NOLLO3S lie on y al osrgze n 2 alo a 6rrOlE N 19 9 MOM NOILO3S LOVLNOD LOVINOO NOILOAS L 9 NOILO3S v MOH 9 MOM Figure 5 3 Contact Block Drawings SM 4574B January 1999 5 6 N 7 Ansaldo STS Parts Lists and Diagrams 5 4 Parts List for Mounting Base N376442 Used on Relay PV 250 with Piece No N322555 002 See Figure 5 4 ASTS USA PART ITEM DESCRIPTION NUMBER NOTE J075828 TE Contact Receptacle 10 to 12 J680181 Wire EN Contact Receptacle 14 to 16 J680165 Wire mE Contact Receptacle 18 to 20 J680179 Wire Meter Test Plug M322965 Insulated Test Plug for opening any coil or contact circuit and for J772383 removing receptacle springs Note A When Mounting Base Complete is ordered a muslin bag of parts 4 1 8 x 5 1 2 is included in the inner carton with the mounting base and instruction prints Bag Contents Tags wem 4 1 4 20 x 1 14 Rd Hd Stl Screws E mm Contact Receptacles solderless for 14 to 16 Quantity wire If other wire size is used request the proper part number as shown in Item 4 when ordering base complete i e N384243 except when using contact receptacles solderless J680181 SM 4574B January 199
5. SHAFT REMOVE COUNTERWEIGHTS TWO THREADS WITHOUT LOCKNUT DSS CAP 4 EXPOSED MIN 2 COUNTERWEIGHTS MAKE SURE APP Y YPTAL TIGHT AGAINST TRUNNION APPLY GLYPTAL EACH OTHER LOCKNUT 15 TIGHT 277 2 nm e a APPLY GLYPTAL E 2 END MAKE SURE TRUNNION LOCKNUT IS TWO THREADS EXPOSED MIN APPLY GLYPTAL TIGHT Y MAKE SURE N DO NOT DISTURB LOCKNUT IS CONTACTS TIGHT AGAINST DURING EMEN COUNTERWEIGHT SERVICING z COUNTERWEIGHTS WITH LOCKNUT BOTTOM VIEW COVER REMOVED Figure 4 5 Inspecting Loose Counterweights and Loose Trunnion Screw locknuts SM 4574B January 1999 Ansaldo STS Parts Lists and Diagrams 5 PARTS LISTS AND DIAGRAMS 5 1 MAIN ASSEMBLY N322555 002 See Figure 5 1 Table 5 1 Main Assembly Parts Listing ASTS USA PART ITEM DESCRIPTION NUMBER NOTE A 1 Frame E 2 Rod Latch 51S 3 Knob Knured Th Nut 006 396 Pin Rol 487047 Tag Calibration 5002036 Pp p Wire Seal P A04303 Sea PJO0708581 Name 7 43759 7 Screw 94 40 x 3 16 Rd Stl F TPPar 3525024 7 Bracket Support M37see0o Screw 10 32 x Flat Stl 3052091 Field Control o N377070 Field Local o 8 69 VaneAssemby N380678
6. 2 2 err ti ads 4 9 Inspecting Loose Counterweights and Loose Trunnion Screw locknuts 4 10 Assembly Drawings for PV 250 Part No 322555 002 5 3 Parts Location for Vane Assembly 380678 5 4 Contact Block Drawings 3 e PE n b Eg EO 5 6 Mounting Base 5 8 Test Operating 1 2 Operating Values at Ideal Phase 00000000 1 2 Crimping Tool for Installing Wires in a Receptacle Contact 2 4 Recommended Cleaning Materials sese 4 1 Main Assembly Parts 5 1 vane Assembly Parts iie eb reete a ee tbe eb nte t te Rd adidas 5 4 SM 4574B January 1999 Y Ansaldo STS General Information 1 GENERAL INFORMATION 1 1 Introduction This manual covers the PV 250 plug in AC vane relay used for track circuit applications Since the relay is a two element AC vane type it must be provided with the appropriate equipment to provide the adequate phase displacement between the local and control track windings The earlier and later designed relays have the same operating characteristics and fit into the same mounting base The design of the PV 250 relay conforms to a
7. enne 4 13 1 1 1 4 13 4 8 Calibration 4 15 4 8 1 Test for Balanced Magnetic 4 15 4 8 2 anaes 4 15 4 8 3 Contact Resistance ite ete eere do Lese o d dn coartada des 4 15 5 PARTS LISTS AND PARTS LOCATION 5 1 6 TECHNICAL SUPPORT iicseiiisee xus euenire anth cance Een eu Euh DE AERE EXER AERE SELLER REF 6 1 Figure 2 1 Figure 2 2 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Table 1 1 Table 1 2 Table 2 1 Table 4 1 Table 5 1 Table 5 2 List of Figures Typical Plug in Relay and Mounting 2 3 Receptacle Contact Springs 2 4 AC Vane Relay Test 3 2 Adjustment of Heel Spring Clips etienne 4 5 Method of Closing in the Lower Heel Spring 4 6 Applicaton of Bending 4 6 Adjustable
8. Screw Trunnion N12488 Bushing 1 529294 2 BushingInsulation 849 Roler 7 7 66 3 Bracket Upper Roller 39483 Bracket Lower Roller Mi61753 PlateCip 9056 Lock Bracket 7 004 Rivet11x5 16Rd Ph Bz 93 Do 0 2 M381128 24 0 Washer Tension T P 012 9 32 O D 3475104 Pin PM3811228 Pn 1 42 0097 1 2 095 Block Terminal _ 7 3 64850 7 Screw 48 32 x 7 16 Rd St 1 2506 IndexngPin 07090 N349711 5502 SM 4574B January 1999 5 1 Ansaldo STS Parts Lists and Diagrams ASTS USA PART ITEM DESCRIPTION NUMBER NOTE Screw 8 32 x 7 8 Rd Stl J052608 48 Arm Operating CE N90324 49 Counterweight 451750025 50 Counterweight Lock Nut M083947 51 Top Cover Device Testing 84546 Screw 6 32 x Y Fil Hd J052485 53 Washer Arc Spr Sth 454 0 54 Term Pre Insul Diag G 707 2 NOTE A When ordering the contact block be sure to include the 0001 suffix with the part number This assures proper processing of the contacts for optimum performance in these relays 5 2 SM 4574B January 1999 LI Ansaldo STS Parts Lists and Diagrams ce 66 06 ve
9. 7 Ansaldo STS 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 SM 4574B PV 250 2 Element AC Vane Relay 25 Hz Part Number Installation Operation Maintenance Copyright 2013 January 1999 Ansaldo STS USA Inc Ansaldo STS Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible to take into
10. 00 652 7276 or by e mail at railteam ansaldo sts us SM 4574B January 1999 6 1 7 Ansaldo STS Technical Support e 5 Ansaldo STS A Finmeccanica Company End of Manual 6 2 SM 4574B January 1999
11. 16 12 54 cm Depth 2 7 16 6 19 cm Old Style Base Depth 1 25 32 4 5 cm New Style Base SM 4574B January 1999 1 3 SX 7 Ansaldo STS General Information AM Ansaldo STS A Finmeccanica Company 1 4 SM 4574B January 1999 Y Ansaldo 575 Installation 2 INSTALLATION 2 1 General Relays plug directly into a mounting base which is secured to a rack The only installation instructions required are for the mounting base 2 1 1 Care in Handling It is very important that these vane relays be handled carefully in order that no undue stresses are applied to the vane structure which might throw the vane out of adjustment A piece of twine which firmly holds the vane is applied to the relay when it leaves the factory The twine must be removed when the relay 15 placed in service and the plug screw must be inserted after removing the twine 2 2 Mounting Base Secure the mounting base directly to the rack using the hardware furnished All wiring terminates at the rear of the mounting base to solderless terminals contact receptacles Mounting base details are shown in the Figure 5 4 2 3 Relay Indexing Relays are factory equipped with indexing pins to prevent insertion of an incorrect relay into a mounting base Each relay is accompanied by an indexing plate which is applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with correspondi
12. 4 4 General Parts Replacement 4 4 4 1 Replacing Contact Block If the contact block is to be replaced by another remove the old block then use a small punch to remove the small dowel pins Attach the new block with the four screws Run a 42 drill 0 0935 Diameter through the dowel pin holes into the epoxy contact block for a total depth of 9 16 1 32 0 4 6 SM 4574B January 1999 Y Ansaldo 575 Shop Maintenance NOTE Replacement contact blocks MUST be of the same general design Carefully install the dowel pins tapping in until they are flush with the aluminum surface If it is necessary to install a used contact block from another relay remove only one of the dowel pins from the aluminum frame Carefully press the block on the remaining pin and fasten in place with the screws One dowel pin will adequately hold the block in place Install the contact block mounting screws and torque them to 10 2 inch pounds Do not over tighten or force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in Subsection 3 3 4 5 Adjustments adjustments of contacts should be made by bending the brass support member with the bending tool applied between the rivets that fasten the contact spring to it Because of the effect of the weight of the contact tips all checks of contact adjustment should be made with the relay in the normal upright position 4 5 1 Recommended To
13. 9 5 7 Ansaldo STS E Parts Lists and Diagrams 4 V d C 6 L 7 gt lt e gt lt 2772 i Y Tt eus EN l h h y N L3 19 E pouce quee f 1 1 2 1 i i j L 1 L E 3 O co E EE E gt Xo 2 Go O E ONDIDOT SONINdS 3719V1d3938 AlddV n Y eo ae EZ 3 gm a t i O 1 n ol 5522 55 8888889 LO Lx gt e o lt OUSLY assi SX MED SM 4574B January 1999 Figure 5 4 Mounting Base Assembly 5 8 Y 7 Ansaldo STS Finmeccanica Company Technical Support 6 TECHNICAL SUPPORT The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 8
14. S Installation Figure 2 1 Typical Plug in Relay and Mounting Base The following is recommended when installing solderless receptacle contact springs after crimping wires 1 Receptacle contact springs must be inserted into the base with the lock side down or lanced tab up see Figure 2 2 2 Make certain that the lanced tab is slightly compressed as the receptacle contact spring is inserted along the top of the cavity The lanced tab could have been bent during handling and if so would not provide the required contact pressure after the relay is inserted If the lanced tab does not touch pull it up slightly using fingers or a suitable tool 3 After insertion pull firmly on the wire to make certain the receptacle contact spring is locked in the cavity NOTE These receptacle springs cannot be used in the Improved One Piece Base SM 4574B January 1999 2 3 Ansaldo STS Installation RECEPTACLE CONTACT SPRING RECEPTACLE SPRING LOCK SIDE LOCK SIDE OLD MOUNTING BASE IMPROVED MOUNTING BASE Figure 2 2 Receptacle Contact Springs Installed 2 4 3 Installing Wires in Receptacle Contact Springs Use the following procedure to ensure a good electrical and mechanical connection between the conductor wire and the receptacle contact spring The following table identifies the correct crimping tool to be used when installing wires in the receptacle contact spring Table 2 1 C
15. account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved ASTS USA spare parts are used as replacements Copyright 2013 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA USA 15219 3120 645 Russell Street Batesburg SC 29006 www ansaldo sts com All rights reserved SM 4574B January 1999 Ansaldo STS Revision History Revision History Re Nature of Revision October 1988 Maintenance Notice Addendum A revision number was not assigned when this revision was made ii SM 4574B January 1999 Ansaldo STS Table of Contents Table of Contents 1 GENERAL 1 1 A a 1 1 1 2 odia 1 1 1 2 General e 1 1 1 2 2 A 1 1 1 2 3 1 1 1 3
16. asting Remove the trunnion lock nuts from the shaft Lower the shaft until the vane edge rests on the machined slot of the contact blocks With the operating arms held clear of the heel springs move the shaft forward and up until the upper back contact heel springs No 4 and 5 can be pushed in back of the shaft Then rotate the counterweight stud toward the contacts and slide the hub out between the heel springs and the roller stop guide This will require a slight deflection of the upper front heel contact springs The crank pins and contact operating arms can then be removed after the vane is out of the relay The foregoing procedure applies to a six front four back relay with a machined slot in the contact blocks to accept the vane and machined slots in the relay frame to allow the trunnion screws to be backed out flush with the inside surface of the support casting SM 4574B January 1999 4 3 Ansaldo STS Shop Maintenance Relays with fewer contacts and machined slots in the contact blocks such as the two front two back relay follow the same general procedure except that removal of the vane past the contacts is more readily accomplished A limited number of early production relays did not have the machined slots in the contact blocks and the relay frame Also a limited number had the machined slot in the contact block but not in the relay frame In order to remove the vane from a relay with no machined slots it is necessary to
17. carefully to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water may be used for removal of accumulated dirt grease etc Inspect the relay exterior for signs of physical damage such as cracked or broken cover cracked or damaged housing and damaged and or missing contact block terminals and indexing pins If severe external damage is found a careful inspection of the interior components should be made for obvious physical damage 4 2 1 Recommended Cleaning Materials Table 4 1 Recommended Cleaning Materials ASTS USA PART NUMBER Burnishing Tool P K Neuses Co No 3 316 J397187 Burnishing Tool P K Neuses Co No N318 Heavy J397187 001 Duty Paper Cleaning Kit 50 strips 5 8 x 772 J793094 Paper Strip strips cut from 67 pound white Springhill J793094 Vellum Bristol Paper Individual items from the kit are also available by ordering the part number designated beside each item Also recommended commercially available Emory Paper Wet or Dry 600 Grit cut in strips Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or Equivalent SM 4574B January 1999 4 1 Ansaldo STS Shop Maintenance NOTE In the final cleaning procedures outlined in the following sections it is recommended that all silver contacts be cleaned first followed by all silver impregnated carbon contacts to prevent contamination of the silver tips with residue that adheres to t
18. ecified in Table 1 1 6 Again slowly increase the output until the vane just touches the top roller and note the value indicated on the AC Ammeter This is the full stroke value and should be within 5 of that specified in Table 1 1 7 Slowly adjust the Variac control to decrease the output until the front contacts open and note the value indicated on the AC Ammeter This is the minimum drop away and should not be less than the percentage specified in Table 1 1 of actual pick up value measured in Step 5 3 3 3 Balanced Magnetic Circuit Test Track relays should be tested from a single phase source of the proper frequency and local voltage in accordance with Figure 3 1 In shop tests of newly overhauled relays it should be possible to meet the values for pick up and full stroke shown in Table 1 1 A drop away value lower than shown as a percentage of the actual pick up obtained indicates excessive friction in the armature pivots the vane crank connections or in the contact operating arms which should be corrected 3 4 CALIBRATION REQUIREMENTS 3 4 1 Test for Balanced Magnetic Circuit With the relay standing on its back so that the vane hangs down with front and back contacts open apply normal voltage and frequency to the local winding There should not be any appreciable movement of the vane particularly no tendency to close the front contacts 3 4 2 In Service Test Calibration requirements will be met when the relay calibra
19. eflect through its full motion with very slight pressure from the operating arm The heel spring has to be handled carefully in order not to distort the thin center member The heel springs should be adjusted so that when the relay is held with the base horizontal and the contact springs pointing downward the heel spring will take a free position when not connected to the operating arm without appreciable bias either toward the front or back contacts 4 5 2 2 Final Contact Adjustments The front and back contact springs should be lined up with their associated heel springs using alignment tool J397164 0020 as explained for the heel contact springs The normal contact adjustment provides 0 031 compression of the front contacts with the vane just touching the upper roller stop 0 025 compression of the back contacts when the vane just touches the lower roller stop and 0 025 opening of the back contacts with the fronts just barely closed These adjustments can be obtained by using the proper section of 3 way bending tool N451151 2401 applied as shown in Figure 4 3 Set the front contacts to have 0 055 opening with the vane resting against the lower roller stop then adjust the back contacts so that they have 0 025 opening with the fronts just barely closed When the vane is up against the upper roller stop the opening of the back contacts should check approximately 0 055 and as a further check each front contact spring should have approximate
20. elay unless it is being converted to a new part number Otherwise a hazard will be created which may compromise safety circuit functions 2 4 Receptacle Contact Springs 2 4 1 Old Style Base Only The N376442 mounting base is normally equipped with the required quantity of solderless receptacle contact springs J680165 and will accommodate one or two 14 or 16 wires It can however be equipped with receptacle contact springs for one or two 10 or 12 wires J680181 or for one or two 18 or 20 wires J680179 Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation NOTE These receptacle springs cannot be used in the Improved One Piece Base 2 4 2 Improved One Piece Base Only The new one piece mounting base N438689 003 with hardware includes a full complement of receptacle contact springs M451142 2702 to accommodate one or two 14 16 wires mounting fasteners and tags It can however be equipped with receptacle contact springs for one or two 10 12 wires M451142 2703 or for one or two 18 20 M451142 2701 Make certain the type of solderless receptacle contact springs that accompany the mounting base before proceeding with their installation Each solderless receptacle contact springs should be inspected for physical damage before proceeding with installation 2 2 SM 4574B January 1999 Ansaldo ST
21. g it into position Care must be used in tightening the trunnion screws so as not to damage the pivots These screws should be adjusted to center the vane in the air gap and to provide 0 010 to 0 016 end play of the vane shaft and then should be locked in position with the lock nuts The stroke of the vane is established by adjusting the roller stop brackets to permit maximum travel of the vane In either extreme position of the vane permitted by the roller stops rollers at the top of the slot the buffer clips on the vane should be 3 32 inch from the cores This provides for maximum travel of the vane and avoids any possibility of the clips ever becoming wedged in the air gap A check should be made that the heads of the crank pins have at least 1 16 clearance from the lock nuts on the trunnion screws when the pin and vane shaft are shifted to make this clearance minimum and the pins securely locked at the split ends so that this clearance cannot be reduced The operating arms must swing free without any tendency to bind 4 4 SM 4574B January 1999 E Ansaldo STS Shop Maintenance 4 4 3 2 Installing Operating Arms Operating arms should be checked to see that warpage does not exceed 0 010 The operating pins and bushings should be assembled and pushed into the clips on the heel contact springs The lower clips should have moderate tension to hold the bushings in place once they are assembled The clips may be closed in by the use
22. g parts in this relay in most cases the relay can be restored to proper operation by dressing and readjusting them 4 4 1 Recommended Tools and Test Equipment Screw Driver Torque Measuring Thickness Gauges 0 001 0 060 in 4 4 2 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the Section 5 for part information and location of parts In general to dismantle the plug in relay proceed with the following sequence 1 Remove relay cover seal 2 Carefully remove plastic cover 3 Remove the vane assembly as required 4 Remove contact block as required 5 Remove Local Control Field as required 4 4 2 1 Vane Assembly Removal Remove the bottom roller stop by bending the left bracket looking at the relay about 1 4 to the left The brackets should not be moved forward or to the rear Disengage the contact operating arms from the clips on the heel contact springs by pulling the arms forward at the lower ends Remove all bushings and pins from these arms Remove the counterweight nuts from the front end of the vane assembly and loosen the look nuts from the trunnion screws To remove the vane place the relay on its mounting surface with the contacts forward A piece of paper may be inserted in the air gap on each side of the vane to protect it from being scratched by the pole pieces during removal Turn the trunnion screws out until they are flush with the inside surface of the support c
23. g the relay case lightly The notches on the arm are spaced to provide the counterweights ordinarily used with the small weight in the notch nearest the vane shaft a counterweight of 100 inch grains as indicated in the second notch 125 inch grains in further 25 inch grain steps to 300 inch grains and 50 inch grain steps to 600 inch grains except an extra notch at 375 inch grains Adjust the counterweight nuts on the vane so that a torque as specified in Table 3 3 is required to just close the front contacts This torque should be measured with the relay in its normal operating position and with all operating arms connected to the heel contacts using an adjustable torque arm At least 1 16 clearance should exist between the end of the counterweight screw and the main support casting The counterweight lock nut shall be securely locked and the end of the screw spread slightly to prevent the nuts backing off 4 5 4 Inspection for Loose Counterweights and Loose Trunnion Screw Locknuts The following procedure involves the opening of a vital relay This procedure must be performed by individuals qualified to work on vital relays Instructions for inspecting for loose counterweights and loose trunnion screw locknuts 1 Remove the bottom cover from the relay This exposes the contact assembly Exercise extreme caution not to disturb the adjustment of the contacts Remove nameplate to gain access to the counterweight assembly on the vane c
24. he cleaning tool after cleaning the silver impregnated carbon contacts When using the paper strip clean the back contacts first and the front contacts Discard the paper strips when dirty 4 2 2 Contact Cleaning Procedure 4 2 2 1 Contacts that are Severely Burned 1 7 Using a 600 grit emery paper strip folded with grit side out so that both contacts be burnished simultaneously stroke the contacts in the direction of the contact wipe Using the burnishing tool stroke the contacts several times in the direction of the contact wipe Place the paper strip between the open contacts then close the contacts and withdraw the paper strip Repeat Step 3 several times if necessary Using the alcohol spray give the contacts a degreasing wash Place the paper strip between the open contacts then close the contacts and withdraw the paper strip Repeat Step 6 several times if necessary 4 2 2 2 Contacts with Heavy Tarnish Slightly Rough or Pitted Surface l Perform the procedure in Section 4 2 2 Steps 2 through 7 4 2 2 3 Contacts with Surface Film or Oxidation not Pitted l Perform the procedure in Section 4 2 2 Steps 6 and 7 4 3 Check Out Procedure Performance Test Perform calibration in accordance with Subsection 3 3 SM 4574B January 1999 Y Ansaldo STS Shop Maintenance 4 4 Repairs and Replacement Since the contacts are the major wearin
25. hile depressing the latch rod After the relay is completely seated in the base release the latch rod and pull on the handle to ensure that the relay has locked in place SM 4574B January 1999 Installation 2 6 M Ansaldo STS A Finmeccanica Company 7 Ansaldo STS SM 4574B January 1999 Ansaldo STS Field Maintenance 3 FIELD MAINTENANCE 3 1 Introduction This section provides the necessary periodic preventive maintenance procedures which must be performed to ensure continuous proper and efficient operation of the PV 250 style relays covered in this manual Field maintenance covers periodic inspections and performance tests 3 2 Periodic Performance Test 3 2 1 Cleaning Before inspecting and testing the relay use a soft cloth to clean the exterior to remove any dirt or dust that may have collected if necessary A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc 3 2 2 Service Requirements 3 2 2 1 General Track relays must be inspected and tested at least every two 2 years The tests and inspections are to include pick up current drop away current and visual inspection of contacts for damage or misalignment corrosion or other contamination of parts loose parts inside of the cover broken seal and cracked or broken cover Relays not passing the above stated tests and inspections must be replaced and not re
26. ies with the track winding is sufficient to provide suitable phase relations Table 1 1 Test Operating Values 5 FULL MIN DROP AWAY STROKE OF ACTUAL P U INCH GRAINS CONNECTED IN VOLTS AMPS VOLTS FIELD 0 574 Tt is recommended that relays be taken out of service if the Drop Away value falls below the value shown for field test 10 PICK UP TORQUE TRACK COIL The values given above are 9 higher than ideal and apply to tests using single phase supply with resistance in series with the track winding Calibration for current values is preferable Table 1 2 Operating Values at Ideal Phase Relations PICK UP FULL STROKE MIN DROP AWAY TRACK COIL OF ACTUAL P U CONNECTED IN VOLTS AMPS VOLTS AMPS Multiple 0 155 0 884 0263 15 90 Seres 0 309 0 443 0525 075 4 The values above are based on ideal phase relations track volts lead line volts 93 and track amperes lead line volts 23 1 3 2 Mechanical Dimensions Height 7 1 16 in 17 93 Width 4 15 16 in 12 54 cm Depth 8 3 8 in 21 5 cm Temperature 40 F 40 C to 185 F 85 C Indexing Determined by relay part number see Section 2 3 Weight 8 0 lbs 3 63 kg Mounting Base N376442 Old Style 37 oz 1 05 kg N438689 003 Improved Style 18 oz 0 51 kg 1 2 SM 4574B January 1999 Ansaldo STS General Information Mounting Base Dimensions Height 7 15 16 20 1 cm Width 4 15
27. ll applicable AAR specifications 1 2 Description 1 2 1 General The PV 250 relay is factory calibrated to operate across a wide environmental range All moving parts are enclosed in a sturdy transparent dust and moisture resistant cover To ensure the relay is inserted in its proper mounting base all relays have indexing pins Relays lock securely in the plug in position 1 2 2 Coils This relay uses a double wound coil that may be used in series or parallel for the control element and a local element that presents the impedance to meet the specifications of specifications of Section 1 3 1 1 2 3 Contacts Contacts of the PV 250 relay are standard low voltage silver to silver impregnated carbon front and silver to silver back See Figure 5 3 for an illustration of the contact assembly 1 3 Specifications This manual provides operating values and the parts list specific to PV 250 Track Relay N322555 002 This relay has the following general specifications 115V Local 25 Cycle 48 48 Turn Track Coil 6F 4B Contacts Local 0 128 amp at 115V The following subsections provide the electrical and mechanical specifications of the PV 250 relays covered in this manual SM 4574B January 1999 1 1 Ansaldo STS General Information 1 3 1 Electrical Specifications Check the current operating values using Figure 3 1 in section 3 3 2 with 15 volts more at the track transformer secondary This will ensure that the resistance in ser
28. ly 0 010 opening from its stop spring When the vane is touching the lower roller stop each back contact spring should similarly have approximately 0 010 opening from its stop spring Recheck calibration per Section 3 3 4 5 3 Counterweight Adjustment The values for vane torque given in Table 3 3 refer to the counterweight torque needed to just balance the vane so that the front contacts just barely close when the relay is in the normal mounted position without current in the windings and the case is tapped lightly Unless the adjustment of the counterweight nut or the heel contact springs has been changed or the operating values are not met this check will not ordinarily have to be made In general it is permissible for the torque to be more than the value shown provided the operating values are correct 4 8 SM 4574B January 1999 Ansaldo STS Shop Maintenance VANE SHAFT Figure 4 4 Adjustable Torque Arm A torque arm Figure 4 4 when used should be slipped on the vane shaft of the relay with the opening of the slot at the bottom as shown Hold it in place by turning the arm which is threaded on the end until it is tight against the vane shaft The small weight on the arm should then be moved to give the desired counterweight and the counterweight nuts on the relay adjusted so that the front contacts of the relay will just make with the torque arm in a horizontal position This can be most easily determined by tappin
29. ng indexing plate is shown in Figure 2 1 The following data defines the indexing that has been established for relays covered by this manual 1 The index code always consists of four figures such as 5501 5502 or 5510 and 15 used for both the relay and the indexing plate on the mounting base The index code for N322555 002 is 5502 2 The index code for each relay can be determined from the relay part number and its suffix which is marked on the name plate attached to the front of the relay The first two digits of the index code are the last two digits of the part number and the second two digits of the index code are the last two digits of the suffix The index number thus obtained should agree with the placement of the indexing pins in the numbered vertical rows on the back of the relay starting with the top pin and reading down SM 4574B January 1999 2 1 Ansaldo STS Installation 3 The index code for each mounting base is determined by the placement of the holes in the numbered vertical rows of the large white nylon indexing plate which is affixed to the front of the mounting base This indexing plate should not be removed from the mounting base unless it is damaged or the indexing is to be purposely changed to accommodate a relay of a different part number Never drill new holes in a base indexing plate which will permit application of relays with different part numbers Never change indexing pins on the back of a r
30. of pliers as shown in Figures 4 1 and 4 2 All bushings should be positioned with the flanges against the heel clips With the side play of the operating arm taken up in either direction the heel spring supporting members should be bent sideways using alignment tool J397164 0020 as shown in Figure 4 3 so that there is clearance of not less than 0 005 nor more than 0 055 to each contact bushing The jaw of the tool should be applied over the portion of the supporting member where it is riveted to the contact spring Check to be sure that all split pins in the operating arm connections are properly spread CONTACT HEEL OPERATING ARM 3 3 NTACT FRING REMOVABLE BUSHINGS HEEL SPRING CLIPS IN UPPER ROWS WHEN MORE THAN ONE ROW IS USED 4 ADJUSTED TO BE PARALLEL AND TO BE FREE ON BUSHINGS WITH MAXIMUM CLEARANCE OF 0 003 HEEL SPRING CLIPS IN BOTTOM ROW OF CONTACTS OF ALL RELAYS AND ON RELAYS WITH ONLY SINGLE ROW OF HEEL CONTACTS TO BE CLOSED IN AS SHOWN USING PLIERS AS PER FIGURE 2 Figure 4 1 Adjustment of Heel Spring Clips SM 4574B January 1999 4 5 Ansaldo STS Shop Maintenance PLIER JAWS WITH STOP TO PROVIDE 5 32 OPENING WHERE THE ENDS OF THE HEEL SPRING CLIPS ARE GRIPPED Figure 4 2 Method of Closing in the Lower Heel Spring Clips 3 WAY BENDING TOOL N451151 2401 gt ASS ALIGNMENT TOOL er J397 164 0020 lt Figure 4 3 Applicaton of Bending Tools 4
31. ols Gap Gauge 0 001 to 0 060 Gram Scale 0 to 30 grams Pliers Heel Clip Bending Tool J397164 0020 Bending Tool N451151 2401 Adjustable Torque Arm N171156 4 5 2 Contact Adjustments 4 5 2 1 Initial Contact Adjustment Front and Back Contacts front and back contact springs should be adjusted to have an initial pressure of 20 grams 10 grams each tip This may be reduced to 12 grams corresponding to 6 grams at each tip as required to meet calibration values On the back contact springs a gram scale applied at the center of the contact tip should just barely move the flexible bronze spring away from the curved stop member The stop member should be bent if necessary not the spring in obtaining this adjustment In order to make this check on the front contact springs using the scale the spring SM 4574B January 1999 4 7 Y Ansaldo STS Shop Maintenance assembly will have to be checked in the inverted position and the pressure should be 18 grams 9 grams each tip to compensate for the weight of the contact tip The contact buttons of the bifurcated springs should close at the same instant b Heel Contacts The design of heel contact provides a flexible hinge arrangement with a rigid assembly on the outer part of the member The thin center spring should be straight and the projection on the upper and lower pressure plates should both bear against the thin center spring This heel spring assembly should d
32. rank 2 Carefully rotate the vane so that the counterweight assembly is visible This will reveal one or more counterweights with or without a locknut on the counterweight screw SM 4574B January 1999 4 9 Ansaldo STS Shop Maintenance 3 NAMEPLATE gt 4 10 As shown in Figure 4 5 check to determine if a counterweight and locknut are tight b at least two threads are visible on the counterweight screw end and c the split screw end is slightly spread apart Tighten any loose counterweights and locknut Perform a visual inspection of the relay Check for rubbing vane debris inside the relay and for obviously misaligned contacts Check to see that the vane is approximately centered and that it has the correct amount of end play 0 010 to 0 016 inch Readjust if required Check the vane for freedom of movement Check to see that the operating arms clips and bushings are in the proper position and are free to move Using a wrench check the trunnion locknuts for tightness Tighten any that are loose Perform an electrical calibration test in accordance with the applicable service manual If the relay passes the field limit requirements outlined in the service manual apply glyptal to the exposed threads of the counterweight screw and trunnion locknut as shown in Figure 4 5 The relay can then be sealed and placed in service MAKE SURE SPLIT STUD IS SPREAD SLIGHTLY APART COUNTER WEIGHT ASSEMBLY
33. remove the contact blocks entirely and lower the support casting sufficiently to allow the trunnion screws to clear the relay frame Relays with only the machined slot in the contact blocks require that the support casting be lowered sufficiently to allow removal of the trunnion screws The support casting should then be put back in place and the vane removed as formerly described in detail If it is necessary to remove the fields from the supporting bracket care must be used in reassembling to make sure that the air gap is between 0 080 inch and 0 085 inch 4 4 3 Reassembly Reassembly is accomplished generally in the reverse order of disassembly Do not over tighten or force parts when reassembling a relay The following Subsections provide additional instructions to be followed during reassembly of this relay Upon completion of reassembly calibrate the relay as directed in Subsection 3 3 4 4 3 1 Installing Vane Assembly The pivots and trunnion bearings should be checked for excessive wear and should be wiped clean with a dry lint less cloth before reassembling the vane The reverse procedure to that for removal should be used The contact operating arms and crank pins should be assembled on the vane cranks first then the vane should be inserted At least one of the trunnion screw lock nuts should be started on the trunnion screws in advance but it may be found necessary to slide the other nut on one end of the vane shaft in order to brin
34. rimping Tool for Installing Wires in a Receptacle Contact Spring CRIMPING OLD STYLE BASE IMPROVED BASE TOOL WIRE SIZE RECEPTACLE CONTACT RECEPTACLE SPRING CONTACT SPRING J397138 10 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Standard M451142 2702 J397188 18 20 AWG J680179 M451142 2701 1 Strip 3 16 in 0 187 in or 0 47 cm of insulation from the end of the wire 2 Place the receptacle contact spring into the jaws of the proper crimping tool When using only one terminal of any wire size use the shortest terminal 3 Partially close the crimping tool jaws against the receptacle contact spring to hold it in place Do not crush the receptacle contact spring barrel at this time 4 Insert the stripped end of wire all the way into the receptacle contact spring barrel Squeeze the tool handles until crimping is completed and the jaws release When using both terminals it is more convenient to attach the first wire to the longest terminal 2 4 SM 4574B January 1999 Y Ansaldo STS Installation 5 Remove the crimped receptacle contact spring from the tool and inspect the connection Make certain that the wire is flush with the crimped barrel and that there are no loose strands of wire 2 5 Relay Insertion Orient the relay to the mounting base with the name plate right side up then plug the relay into the base The relay should be pushed firmly against the mounting base w
35. tion values are the same as those given in Table 1 1 of this manual After any shop adjustments are made check the calibration values Subsection 3 3 and if they are not within the values given in Table 1 1 of this manual the relay should not be placed in service 3 4 3 Contact Resistance Resistance of front contacts should be measured with the armature in its full stroke position and resistance of back contacts should be measured with the armature fully released Cleaned contact resistance should not exceed the following values SM 4574B January 1999 3 3 Ansaldo STS Field Maintenance Front Back Type of Contacts Contact Silver to Silver Impregnated Carbon 0 09 Silver to Silver ME Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive loading or an accidental short through the contacts When contacts must be dressed refer to Subsection 4 2 1 and 4 2 2 3 4 SM 4574B January 1999 Ansaldo STS Shop Maintenance 4 SHOP MAINTENANCE 4 1 Introduction This section provides the information necessary to perform shop level repairs of the PV 250 style relays covered in this manual In general relays arriving at the shop for repair have been checked in the field and have been found to perform unacceptably or have been physically damaged 4 2 Cleaning and Inspection Before inspecting the relay and initiating repairs use a soft cloth to clean the exterior
36. turned to service until the operating characteristics and conditions are in accordance with ASTS USA specifications 3 2 2 2 In Service Test Track relays not meeting test and or calibration specifications must be removed from service for shop repair 3 3 CALIBRATION 3 3 1 Recommended Test Equipment Variable autotransformer Variac 115 V 1 0 Amp AC Ammeter AC Voltmeter 2 Resistors variable 0 200 ohms 100 watts SPST switch SM 4574B January 1999 3 1 mo Ansaldo STS Field Maintenance 3 3 2 Relay Test Procedure NOTE When performing calibration set local voltage as specified to within 1 115 VAC 25 Hz O ISOLATED LINE ON OFF S1 T1 R RELAY UNDER TEST New Style Base Contacts Shown with Parentheses Old Style Base Contacts Shown without Parentheses Figure 3 1 AC Vane Relay Test Circuit 1 Connect the circuit shown in Figure 3 1 with the control windings in parallel 2 Connect circuit to 115V 190 AC 25 Hz line 3 Set Variac output control to minimum output setting 4 At full output of Variac adjust resistor so the current flowing is 10 above full stroke value 3 2 SM 4574B January 1999 Ansaldo STS Field Maintenance 5 Slowly adjust the Variac control to increase the output until the front contacts just close and note the value indicated on the AC Ammeter This is the pick up value and should be within 10 of the pick up value sp
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