SM-9080 - Ansaldo STS
Contents
1. esse esee ee ennneesennkeanantaanntnannneanntas 4 9 Parts List for PN 250F Relay oeeo an aE EE EAT EA EEE EE EAA 5 1 SM 9080 Rev 1 July 2011 AnsaldoSTS General Information 1 GENERAL INFORMATION 1 1 Introduction This manual provides installation and operation information for the PN 250F plug in DC Flasher Relay which is used as a flasher in signal systems The PN 250F relay N40116101 Figure 1 1 was developed as a plug in replacement for ASTS USA s PF 256 relay N322561 XXX The new PF 250F relay combines a solid state flasher with electromechanical relay contacts to provide a flexible reliable relay to control the flashing of signals As a plug in replacement for the PF 256 relay except for the flasher frequency selection described in Section 2 3 no wiring or system changes are required to exchange the relays Figure 1 1 PN 250F Relay SM 9080 Rev 1 July 2011 1 1 General Information AnsaldoSTS 1 2 Description The PN 250F relay is an electronically driven biased DC relay intended for use in signal flasher service It uses an electronic flasher module to operate the relay at a selectable flash rate of 45 or 60 flashes per minute Because the flash rate is electronically controlled the rate is constant and is no longer dependent on mechanical adjustments The electronic flasher package is mounted internally and is externally adju2. Relay with Flasher Module 4 6 3 1 Recommended Test Equipment The recommended test equipment for the flasher test 1s listed 1n Table 4 3 Table 4 3 Recommended Test Equipment for the Flasher Test NOMENCLATURE PART MODEL TYPE NO Power Supply Variable 0 40 Vdc Digital Multimeter Fluke Model 87 or equivalent SPST Switch S2 DPDT single pole single throw Switch Counter Redington R9 3206 or equivalent On Time Meter PD 30 Simpson TS 111 4 6 3 2 Procedure Connect the flasher relay test circuit as shown in Figure 4 4 jumper terminals 2F and 2A on the back of the relay base and proceed as follows 1 Set M1 to appropriate DC voltage range 2 Turn DC power supply on and adjust for 12 0 1V dc output 3 Set switch S1 on the ON position and simultaneously begin to time a period of three minutes 4 At the end of precisely three minutes set switch S1 to OFF and note the reading at the counter 5 Divide the counter reading by three The resultant rate should be 45 5 counts per minute Reset the counter to zero and remove the jumper from terminals 2F and 2A 7 Repeat Steps 3 and 4 8 Divide the counter reading by three The resulting rate should be 60 5 counts per minute 9 With switch S1 set to OFF and the relay operating at 12 volts connect leads of the On Time Meter across the heel and front contacts and then across the heel and back contacts The front and back contac
3. 4 AnsaldoSTS Shop Maintenance Le ll tN P CU eo D a a b ND gr 17 SJ EU al ZK el 45 he a a a E DL lem a 68 65 2675 Q ako GO Aj ee ae Figure 5 1 PN 250F Relay with One Piece Molded Base l SM 9080 Rev 1 July 2011 5 3 Parts List A AnsaldoSTS S E AnsaldoSTS 5 4 SM 9080 Rev 1 July 2011 kal 7 AnsaldoSTS Technical Support 6 RAIL TEAM AND 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 1 800 652 7276 or by e mail at railteam Cansaldo sts us SM 9080 Rev 1 July 2011 6 1 RAIL Team and Technical Support AnsaldoSTS Sy 4 AnsaldoSTS End of Manual 6 2 SM 9080 Rev 1 July 2011
4. 5 oz Dimensions Height 7 15 16 20 16 cm Width 4 15 16 12 64 cm Depth 1 25 32 4 52 cm Coil Resistance 87 5 ohms SM 9080 Rev 1 July 2011 General Information 1 3 w 3 General Information 4 AnsaldoSTS kal y AnsaldoSTS 1 4 SM 9080 Rev 1 July 2011 kal AnsaldoSTS Installation and Operation 2 INSTALLATION AND OPERATION 2 1 General To avoid personal injury or equipment damage observe all electrical safety precautions when installing the PN 250F relay Power does not have to be turned off to insert the PN 250F into the existing base As stated the PN 250F relay is a plug in replacement for the PF 256 relay The relay base wiring is exactly the same as the PF 256 so no wiring changes are necessary except for flash rate selection The wiring terminations for the old style Bakelite base terminal are A and A The new style base terminal designations are 1 A and IF See Figure 2 1 DIRECT CONNECTION TO COIL FOR READING CALIBRATION VALUES IN THE FIELD BATTERY BATTERY FLASH RATE SELECTOR JUMPER INSTALLED FOR A 45 fpm FLASH RATE Figure 2 1 Relay Base showing Wiring Terminations SM 9080 Rev 1 July 2011 2 1 aN Installation and Maintenance AnsaldoSTS 2 2 Mounting Base The mounting base is secured directly to
5. 8 Check that all Full Stroke Pick Up and Release that all stops are open This opening should be approximately 0 008 9 With the armature held in the mid point position with neither fronts nor backs making check to see that the free play between the heel spring and the driver is 0 010 or less If the free play is excessive adjust the height of the clip as shown in Figure 4 2 Re l di MEI A Figure 4 2 Heel Contact Springs SM 9080 Rev 1 July 2011 4 5 GH Shop Maintenance AnsaldoSTS 4 5 4 Contact Adjustment Old Blocks For original factory installed blocks adjust the contacts per Steps 6 and 7 of Section 4 5 3 above and check the stop opening per Step 8 If the 0 008 opening cannot be maintained then complete contact adjustment must be performed 4 5 5 Hold Down Force With the relay in the normal upright position and deenergized a force of at least 190 grams Table 4 4 should be required to move the armature away from the permanent magnet assembly This upward force should be measured with a gram gage at the bottom end of the centermost contact driver The hold down force can be increased if necessary by bending the shunting strip which is fastened to its forward face away from the permanent magnet If one or both of the two vertical screws Which fasten the permanent magnet assembly to the relay frame is steel a further increase in hold down force can be obtained by changing t
6. equipment required to fully charge the magnet and then age it to its best working strength 4 4 2 Reassembly Reassembly is accomplished generally in the reverse order of disassembly The following paragraphs provide additional instructions to be followed during reassembly of the relay 4 4 3 General Parts Replacement NOTE Do not over tighten or force parts when reassembling the relay Upon completion of reassembly calibrate the relay per Section 4 6 4 4 3 1 Replacing Contact Block 1 If the contact block is to be replaced remove the old block then use a small punch to remove the small dowel pins that secure the block Attach the new block with the four screws Run a 42 drill 0 0935 Dia through the dowel pin holes into the epoxy contact block for a total depth of 9 16 1 32 0 SM 9080 Rev 1 July 2011 4 3 GH Shop Maintenance AnsaldoSTS NOTE Replacement contact blocks MUST be of the same general design 2 Carefully install the dowel pins tapping in until they are flush with the aluminum surface 3 Ifitis 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 4 Do not over tighten or force parts when reassembling a relay Upon completion of reassembly calibrate th
7. rate relay highway crossing lights flashing After not more than 5 million operations or 4 years whichever occurs first for a 60 flash rate relay wayside signal light flashing The tests and inspections are to include flash rate 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 The contact surfaces will normally roughen and appear burned due to service The contacts should be examined for cratering or for material transfer which could result in mechanically interlocking the contacts Relays having contacts with severely eroded surfaces indicating more than the loss of 50 of the contact thickness should be replaced The flash rate is controlled by electronic package and is relatively independent of the relay s calibration so it is not necessary to replace the electronics should the relay need be removed from service for repair If the flash rate is outside the requirements or is severely unbalanced the electronic package must be replaced Relays not passing tests and inspections must be replaced and not returned to service until the operating characteristics and conditions are in accordance with ASTS USA specifications SM 9080 Rev 1 July 2011 3 1 E Field Maintenance AnsaldoSTS 3 2 2 2 In Service Visual Inspection When conducting a visual inspection at the intervals stated in Sect
8. AIL TEAM AND TECHNICAL SUPPORT rsssssseneeennnnneennnnnneennnnnneennnnnneennnnnesennnnneenns 6 1 Figure 1 1 Figure 2 1 Figure 2 2 Figure 2 3 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 5 1 Table 1 1 Table 2 1 Table 4 2 Table 4 3 Table 4 4 Table 4 5 Table 5 1 List of Figures PN 250F Relay accused DT dn LALL ALL en MALL AE 1 1 Relay Base showing Wiring Terminations A 2 1 New Mounting Base for PN 250F Relays ccccceeeeeeeeeeeeeeeeeeeaeeeeeeaaeeeseeaeeeeeenaeeeeeeaas 2 4 Receptacle Spring Installed AAA 2 5 Assembly of Permanent Magnet and Adjustment of Armature Position Indicator 4 1 Heel Contact Spi gS sage a a bed eazactdadie tacgavacciudiueeustcasac EAE 4 5 PN 250F Relay Test Circuit cccceccceeeeeceeneeceeeeecaeeeeaaeceeeeesaeeesaaeedeeeeseaeeeeaeeseeeseeeeess 4 7 Flasher Relay Test Cireunt eee sseeeseeeeesnennsenktaanktnannknnnnnKankttaanknlannkanntio 4 9 PN 250F Relay with One Piece Molded Base 5 3 List of Tables Electrical Specifications a ss aye eit vie an GY eva 1 2 Base Wire Combinations eeecceeeeeeceeeeeneeceeeee cae eeeaaeeeeeeesaeeesaaesesaaeseeeeeseaeeesaeeseneeeeaees 2 4 Recommended Test Equipment for Calibration ccccccceceeeeeseeeeeeeeseeeeeseaeeeeneeeeeeee 4 6 Recommended Test Equipment for the Flasher Test 4 8 Mechanical Adjustments and Hold Down Torgoue 4 9 Calibration Values Single Coil Relays
9. DU 1000 Technology Drive Pittsburgh PA 15219 AnsaldoSTS 645 Russell Street Batesburg SC 29006 SM 9080 PN 250F Relay Plug In Replacement for the PF256 Flasher Relay ASTS USA Part No N40116101 PN 250F Z FA DIRECT REPLACEMENT PS Installation Operation Maintenance Copyright 2011 SM 9080 Rev 1 Ansaldo STS USA Inc July 2011 N d AnsaldoSTS 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 wa
10. Tarnish Slightly Rough or Pitted Perform Steps 2 through 7 of Section 4 2 1 1 1 4 2 2 Contacts With Surface Film or Oxidation Not Pitted Perform Steps 6 and 7 of Section 4 2 1 1 1 4 3 Check Out Procedure Performance Test Test the calibration of the relay in accordance with Section 4 6 4 2 SM 9080 Rev 1 July 2011 Ei AnsaldoSTS Shop Maintenance 4 4 Repairs and Replacement Since the contacts are the only wearing parts in this relay in most cases the relay can be restored to proper operation by dressing Section 4 2 1 and readjusting them Section 4 5 3 or 4 5 4 as applicable 4 4 1 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the Parts List Appendix A for part information and location of parts In general to dismantle the plug in relay proceed as follows 1 Remove relay cover seal 2 Carefully remove the plastic cover 3 Remove disassemble the relay components as required 4 Remove contacts contact block as required 5 Remove the permanent magnet as required NOTE These magnets are of a special alloy that permits retention of proper strength indefinitely if not abused When not in place on relays magnet assemblies should be kept separated from other magnetic objects and the screws which hold the extension to the magnet should be kept tight Should a magnet become weakened it should be returned to the factory for recharging where there is special
11. e relay as directed in paragraph 4 6 4 4 3 2 Permanent Magnet The polarity of the magnet should be such that the top end farthest from the two notched holes will attract the end of a compass needle which points toward geographic South see Figure 4 1 The permanent magnet assembly should be applied to the relay as shown in Figure 4 1 making sure that the shunt between the magnet and the magnet extension is touching the pole piece Tighten the two long screws holding the magnet assembly to the pole piece sufficiently to straighten the curved strap against the magnet Bend the nut locks securely up against the sides of the screw heads 4 5 Adjustments NOTE All adjusting and testing must be done with the relay in its normal upright position 4 5 1 Recommended Tools and Test Equipment Thickness Gauges 0 001 in to 0 200 in Gram Gauge 250 Grams Screw Driver Torque Measuring 4 5 2 Magnet and Magnet Extension Insert a 0 130 inch spacer between the stop pin and the pole face and adjust the permanent magnet extension so that it touches the Teflon back stop tape or the back stop pins whichever is present on the bottom of the armature 4 4 SM 9080 Rev 1 July 2011 AnsaldoSTS Shop Maintenance After adjustment the magnet and magnet extension should be centered on each other and on the armature On relays without back stop pins the bottom of the armature should fit flush on the surface of the magnet ext
12. ension with no air gaps On relays with back stop pins the air gap should be of uniform width across the surface of the magnet extension 4 5 3 Contact Adjustments on Relays With One Piece Molded Driver and New Contact Blocks Applied by Customers The contact block or blocks should be installed in the relay frame with screws tightened by means of a torque measuring tool to 10 2 inch pounds The dowel pin hole or holes in the relay frame must be so located that the completed relay will fit freely into its proper mounting base without receptacle contact springs Proceed as follows to apply new contact locks 1 Set all contact stops to be open 2 With a 0 0153 spacer under the core pin set all front contacts to be closed All front contacts should open on a 0 058 spacer 3 With a 0 077 spacer under the core pin set all back contacts to be closed All back contacts should be open on a 0 072 spacer 4 Using Tool 1451151 2801 remove the driver and adjust the heel springs so that they are neither touching the front nor the back contacts 5 Reinstall the driver and recheck the settings per Steps 2 and 3 above 6 With a 0 042 spacer under the core pin adjust the contact stops so that all front contacts are closed With a 0 047 spacer all fronts should be in their open positions 7 With a 0 088 spacer under the core pin adjust the back stops so that all backs are closed With a 0 083 spacer all backs should be open
13. esaeeneeeeeneees 4 2 4 2 2 Contacts With Surface Film or Oxidation Not Pitted 00 0 0 eeeeeeeeeeteeeeeeeeeereeeeteeees 4 2 4 3 Check Out Procedure Performance Teen 4 2 4 4 Repairs and Replacement c cccecsecceceeseeeeeeeeeeeeeeeseeeeeeaneeeeeseaeeeeeseneeseenenaeeeeseneeeeeneneeeeenenes 4 3 4 4 DISASSEMBLY EE 4 3 4 4 2 Meassembly EE 4 3 4 4 3 General Parts Replacement 0 ccceccceeeeeeeceeeeeeeeeeeeeeeseeeesaaeeeeaeeseeeeeseaeeseaeeseeeeeeeees 4 3 E E eu 4 4 4 5 1 Recommended Tools and Test Equipment sssssssssssirsserrssrrrssrirnnsinrnnstennssennnsnnn 4 4 4 5 2 Magnet and Magnet Extension esee eseeeseseennenesennnnntstaanknknannknttaankkkeiaas 4 4 4 5 3 Contact Adjustments on Relays With One Piece Molded Driver and New Contact Blocks Applied by Customers sse e sinen esinnnteannnknannnennnktennktaanknnaankIanntaano 4 5 4 5 4 Contact Adjustment Old BIOCKS cccccceccesseeecseneeeeceesaeeesseeaeeeeeesaeeeesesaeeeesesaeeeeeeaas 4 6 bb Hold Down FOCE netarik e A esik A ree 4 6 SM 9080 Rev 1 July 2011 iil Table of Contents d AnsaldoSTS Ee ee Oe EE 4 6 4 6 1 Recommended Test Eoupment 4 6 4 6 2 Calibration Procedure 4 6 4 6 3 Flash Rate Test Relay with Flasher Module 00 ec cceeeeseeeeeeeeeeeeeenaeeeeeeaeeeeeenaeeeeneaas 4 8 4774 Calibration e EE 4 8 4 7 1 Calibration Values 4 8 4 8 Gontact Ee EE EEN 4 9 5 PARTS EIS KEE 5 1 6 R
14. geet Eesen 1 3 2 INSTALLATION AND OPERATION sssesesoennsnnnnnnnannnnhennnnnnnnnnnnnnnennanneannnnnnnnnnnnnrtnnn 2 1 21 ET EE 2 1 252 MOUNTING B sa eeen a A IAS er AI ASO 2 2 CN EE 2 2 E Get LEE 2 2 KE El EL e EE 2 2 2 6 Receptacle Contact Springs c cccccccceeeceeeeeeeeeeeceeeeecaeeeeaaeseeeeeseaeeesaaeeseaeeseeeeesaeeeeaeeseaeeeeaees 2 2 2 631 Old Style Base Only eeneg gg en a ch ave eel aie 2 2 2 6 2 Improved One Piece Base Only ccccceeecceeeeeeeeeeceeeeeceeeeeaaeeeeaeeseeeeeseeeesaeeseeeeeeetess 2 3 2 6 3 Installing Wires in Receptacle Contact Springs cccccccseeeeeseeeeeeeeteteeeeeeeeeneeeeeeeees 2 3 2 74 RELAY INSSMION RE 2 5 Ze sg EKMAN ON WE es abound adi A dates ded inks 2 5 35 FED MANTENAN OE eege genee ees cuctces sects stuedudedensaued cute aaa Eaa aaa Aaa 3 1 KSE rte ed 3 1 3 2 Periodic Performance Teston inrter LAA A 3 1 KREIEN 3 1 3 2 2 Service Requirements cccecceeeeeeeeee cence eeeaeeeeaae scence sae eeceaeseeaaeseaeeeseaeessaaeseeneeeseetess 3 1 A SHOP MAINTENANCE 6 io caccecocccseceseceeiesencessccceseeteszecessececaneteanecesacceesuatezsetesseceessateceechtaseresacteszatersezees 4 1 AV MMO ee 4 1 4 2 Cleaning and Inspection cececeeeeeeeeeneeeeeaeeeeeeeceeeeecaaeeesaaeseeeeseaeeecaaesseaeeseeeescaeeesaeeseneessaees 4 1 4 2 1 Cleaning Relay Contacts 0 ccccccsceeeeeeeeeeeeceeeeeeae scenes seas eeseaeeeeaeeseeeeeseaee
15. h 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 Always attach the first wire to the longest terminal This ensures that a second lead may be attached to the receptacle contact spring at a later time SM 9080 Rev 1 July 2011 2 3 aN a Installation and Maintenance AnsaldoSTS 5 Remove the crimped receptacle contact spring from the tool arid inspect the connection Make certain that the wire is flush with the crimped barrel and that there are no loose strands of wire 15 16 PN 250 Figure 2 2 New Mounting Base for PN 250F Relays Table 2 1 Base Wire Combinations Crimping Tool Wire Size Old Style Improved Base Receptacle Amp Type Receptacle Contact Spring J397138 10 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Std M451142 2702 J397188 18 20 AWG J680179 M451142 2701 2 4 SM 9080 Rev 1 July 2011 AnsaldoSTS Installation and Operation 2 7 Relay Insertion Orient the relay to the mounting base with the push rod to the left hand side then plug the relay into the base The relay should be pushed firmly against the mounting base while depressing 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
16. hat it will replace either the PF 256 N322561 001 or the PF 256 N322561 002 The relay is factory equipped with indexing pins to prevent insertion of an incorrect relay into a mounting base The relay is indexed so that it will plug into the current position of the N322561 001 or N322561 002 2 6 Receptacle Contact Springs 2 6 1 Old Style Base Only The old style mounting base was normally equipped with the required quantity of J680165 solderless receptacle contact springs and would accommodate one or two 14 or 16 wires It could 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 2 2 SM 9080 Rev 1 July 2011 Ei AnsaldoSTS Installation and Operation Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation 2 6 2 Improved One Piece Base Only The one piece mounting base Figure 2 2 with hardware N438689 001 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 18 20 wires M451142 2701 or for one or two 10 12 M451142 2703 wires Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation Each solderless rece
17. in place 2 8 External Wiring The pin outs of the relay are the same as for the PF256 it replaces except for the flash rate selection jumper see Figure 2 1 MOUNTING BASE Ke EZ WIRES RECEPTACLE SPRING CONTACT Figure 2 3 Receptacle Spring Installed SM 9080 Rev 1 July 2011 2 5 Installation and Maintenance 4 AnsaldoSTS a y AnsaldoSTS 2 6 SM 9080 Rev 1 July 2011 ay 4 AnsaldoSTS Field Maintenance 3 FIEID MAINTENANCE 3 1 Introduction This section provides the necessary periodic preventive maintenance procedures which must be performed to ensure continuous proper and efficient operation of the PN 250F relay Field maintenance covers periodic inspections and performance tests 3 2 Periodic Performance Test 3 2 1 Cleaning Before inspecting and testing the relay if necessary use a soft cloth to clean the exterior to remove any dirt or dust that may have collected A cleaning solution safe for use with plastics may be used for removal of accumulated dirt grease etc 3 2 2 Service Requirements 3 2 2 1 General NOTE Maintenance shall be performed in accordance with railroad company guidelines Minimum guidelines set forth in FRA CFR 49 Part 234 263 and Part 236 106 require the flasher relay to be inspected once upon installation and as follows After not more than 10 million operations or 4 years whichever occurs first for a 45 flash
18. ion 3 2 2 1 it is recommended that flasher relays be removed from service for shop repairs if one or more of the following conditions are observed 1 The flash rate is not within 5 FPM of selected flash rate This does not indicate a complete failure the relay can be left in service if the flash rate is not objectionable 2 The on time of the lamps becomes objectionably unbalanced 3 Ifthe contacts are worn to such a degree that failure is imminent 3 2 2 3 Test Procedures If a flasher relay is removed from service based on the observation s stated in Section 3 2 2 2 additional testing may be conducted to confirm the need for sending the relay to the ASTS USA Service Shop for shop repairs Measure the Drop Away Full Drop Away and Full Stroke Pick Up current values using the procedure in Section 4 6 2 If the Drop Away current value falls below 67 of the value given in Table 4 5 or if the Full Drop Away current value falls below 33 of the value given in Table 4 5 or if the Full Stroke Pickup current is more than 110 of the value given in Table 4 5 the relay is considered to be out of calibration and needs shop maintenance The flash rate and on time values can be measured using the procedure given in Section 4 6 2 3 2 SM 9080 Rev 1 July 2011 AnsaldoSTS Shop Maintenance 4 SHOP MAINTENANCE 4 1 Introduction This section provides the information necessary to perform shop level repairs on the PN 250F style
19. o bronze screws The steel screw J463078 has dull tin plating and its head is 3 32 inch thick The bronze screw M327179 has brighter nickel plating and its head is 1 8 inch thick Any change in the hold down force will affect the relay calibration as discussed in Sections 4 6 and 4 7 4 6 Calibration The relay is calibrated with the flasher module bypassed The flasher needs no calibration 4 6 1 Recommended Test Equipment The recommended test equipment is listed 1n Table 4 2 Table 4 2 Recommended Test Equipment for Calibration NOMENCLATURE PART MODEL TYPE NO Power Supply Variable 0 40 Vdc Digital Multimeter two required Fluke Model 87 or equivalent DPDT double pole double throw S1 SPST Switch S2 4 6 2 Calibration Procedure Proceed as follows to calibrate the relay 1 Connect the circuit as shown in Figure 4 3 2 Set the voltmeter to the appropriate voltage range 3 Set the ammeter to the appropriate current range 4 Set switch S1 to its Normal position 4 6 SM 9080 Rev 1 July 2011 N A nsaldoSTS Shop Maintenance 5 Turn the dc power supply on and close switch S2 10 11 12 Observe the ammeter and adjust the dc power supply output control to obtain the charge current reading indicated in the Amps portion of the Charge column in Table 4 5 Note that the relay energizes and remains energized as the voltage increases Set switch S1 to its Reverse po
20. osed Open Closed Open in in in in PN 250F 0 0310 0 130 190 0 042 0 047 0 088 0 083 Table 4 5 Calibration Values Single Coil Relays Relay Ohms Charge Min Drop Min Full Drop Max Pick Up amp Full Style Amp Away Amp Away Amp Stroke Amp 250F 87 5 0 260 0 022 0 006 0 065 SM 9080 Rev 1 July 2011 4 9 GH w Shop Maintenance 7 AnsaldoSTS Sal 4 AnsaldoSTS 4 10 SM 9080 Rev 1 July 2011 E AnsaldoSTS Shop Maintenance 5 PARTS LIST Table 5 1 gives the parts tabulation for the PN 250F relay and Figure 1 1 shows the location of the parts Table 5 1 Parts List for PN 250F Relay lemNo PartNumber o Ww60 40 PatDescription 8 06 J04876 Roll Pin Stainless Steel Cd 08 M436567 Plate Mounting 6 4 09 ts 435315 HingePlate O Shim 40 B amp S Gage Brass Screw 8 32 x 14 Round Head Screw 8 32 x 4 Round Head Screw 14 Hex Head Bronze Rd 28 Washer 30 31 Screw 8 32 x Round Head 32 Lock Bolt Monel 33 34 35 36 SM 9080 Rev 1 July 2011 5 1 Zu Parts List y AnsaldoSTS Item No PartNumber Got Description 52 N4511370501 Armature o y O 60 J475200109_ Washer 8 Plate Stainless Steel Screw 4 Hex Head Steel 66 M275388 Lock Nut 0 006 x 5 16 Steel e 3751247 Sponge Rubber seal i O Not shown in Figure 5 1 5 2 SM 9080 Rev 1 July 2011 N
21. ptacle contact spring should be inspected for physical damage before proceeding with installation The following is recommended when installing solderless receptacle contact springs 1 Receptacle contact springs must be inserted into the base cavity with the lock side down Figure 2 3 2 Make certain that the lanced tab is slightly compressed when the receptacle contact spring is inserted along the top of the cavity The lanced tab could have been bent during handling and therefore might 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 4 Have available the contact removal tools J772383 New Style Yellow J077931 Old style Red 2 6 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 Table 2 1 identifies the correct crimping tool to be used when installing wires in receptacle contact springs 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 3 Partially close the crimping tool jaws against the receptacle contact spring to hold it in place Do not crus
22. r after adjustments have been made to meet calibration requirements the contacts should be cleaned in accordance with the procedures presented below NOTE When using the paper strip clean the back contacts first then the front contacts last Discard the paper strips when dirty Table 4 1 Recommended Cleaning Materials Material Part Number Burnishing Tool P K Neuses Co No 3 316 J397187 Burnishing Tool P K Neuses Co No 3 318 Heavy Duty J397187 001 Paper Strip 50 strips cut from 67 white Springhill Vellum Bristol Paper or equivalent J793094 Emery Paper Wet or Dry 600 grit cut in strips Commercially Available Denatured Alcohol Commercially Available 4 2 1 1 1 Contacts That Are Severely Burned 1 Using a 600 grit emery paper strip folded with the grit side out so that both contacts can be burnished simultaneously stroke the contacts in the direction of contact wipe 2 Using the burnishing tool stroke the contacts several times in the direction of contact wipe 3 Place a paper strip between the open contacts then close the contacts and withdraw the paper strip 4 Repeat Step 3 several times if necessary Using denatured alcohol give the contacts a degreasing wash 6 Place a paper strip between the open contacts then close the contacts and withdraw the paper strip 7 Repeat Step 6 until the paper strip is clean after being withdrawn 4 2 1 2 Contacts With Heavy
23. relay In general relays arriving at the shop for repair have been checked in the field and have been found to perform unacceptably or have been physically damaged 4 2 Cleaning and Inspection Before inspecting the relay and initiating repairs use a soft cloth to clean the exterior carefully to remove any dirt or dust that may have collected A safe cleaning solution or alcohol and water may be used for removal or accumulated dirt grease etc Inspect the relay exterior for signs or physical damage such as a cracked or broken cover cracked or damaged housing and damaged and or missing contact block terminals and indexing pins If severe damage is found a careful inspection or the interior components should be made for obvious physical damage Remove the cover and clean the surface between the armature and the pole races especially the stop pin area see Figure 4 1 using a lint free cloth and alcohol Proceed with relay contact cleaning using the recommended cleaning materials listed in Table 4 1 ADJUSTMENT SHUNT MAGNET MAGNETIC SHUNT STOP PIN POLE PIECE MAGNET EXTENSION PHOSPHOR BRONZE OR STEEL SCREW AS REQUIRED E NOTCHES IN MAGNET Figure 4 1 Assembly of Permanent Magnet and Adjustment of Armature Position Indicator SM 9080 Rev 1 July 2011 4 1 GH Shop Maintenance AnsaldoSTS 4 2 1 Cleaning Relay Contacts After contacts have been dressed and o
24. rranties Within the scope of the attached manual it is impossible to take into account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved ASTS USA spare parts are used as replacements SM 9080 Rev 1 July 2011 pu Revision History AnsaldoSTS Revision History DATE NATURE OF REVISION May 2003 Initial Issue Revised Sections 3 2 2 1 3 2 2 2 July 2011 3 2 2 3 4 6 2 4 6 3 1 4 6 3 2 and 4 7 1 Copyright 2011 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA USA 15219 3120 645 Russell Street Batesburg SC 29006 www ansaldo sts com Al rights reserved ii SM 9080 Rev 1 July 2011 N m AnsaldoSTS Table of Contents Table of Contents 1 GENERAL INFORMATION srsesesoonnsnnnennnnennnnnennnnnennnnennnneeannnennnneennneennnnrannnnennneennnnrtn 1 1 lal lrittoduotlon sse apoga o noo Ea noda eg as ba KERA bens A Ta ba EA ka E knn fak Oda ian beLa Bia E ent 1 1 152 DOSCrIPTION pi pe GN LI ILA 1 2 UN Ee EE 1 2 1522 Contacts sd I EA ed es E EA es 1 2 1533 Eletll6al ss A OA ea eh te 1 2 Tae Mechanical ery 5 1 ornata po LASERO oo er
25. sition The relay should deenergize Set switch S1 to its Normal position The relay should again energize Adjust the dc power supply output control to reduce the current at a rate so as not to overshoot the actual value and measure the Drop Away Which is the value at which the front contacts open refer to Table 4 5 for the acceptable value Further reduce the dc power supply output control setting at a rate so as not to overshoot the actual value and check the minimum Drop Away with Full Back Contact Compression refer to Table 4 5 for the acceptable value Reduce the current to zero then open the circuit momentarily using switch S2 Adjust the dc power supply output control to increase current at a rate so as not to overshoot the actual value and obtain Pick Up which is the value at which the front contacts make Refer to Table 4 5 for the acceptable value Further increase the dc power supply output control at a rate so as not to overshoot the actual value to obtain the relay Full Stroke value which is the value at which the armature is tight up to its stop pins Frequently Pick Up and Full Stroke will be the same value AMMETER o Bj TERMINAL 1B RELAY POWER VOLTMETER v NORMAL REVERSE UNDER SUPPLY TEST TERMINAL 1F LA Figure 4 3 PN 250F Relay Test Circuit SM 9080 Rev 1 July 2011 4 7 GH Shop Maintenance AnsaldoSTS 4 6 3 Flash Rate Test
26. stable to provide 45 or 60 flashes per minute The contact combination is 4NR silver alloy The armature assembly in the PN 250F is hinged eliminating the pivot screws and the wear associated with the pivots used in the PF 256 This results in a more reliable unit with longer service life 1 2 1 Coils The PN 250F relay has a coil resistance of 87 5 ohms 1 2 2 Contacts The four normal and four reverse contacts are silver alloy to silver alloy rated at 5 amperes at 30V dc or 175V ac 1 3 Specifications The following paragraphs provide the electrical and mechanical specifications for the PN 250F relay 1 3 1 Electrical The electrical specifications for the PN 250F relay are presented in Table 1 1 Table 1 1 Electrical Specifications Part No Contacts System Power Flash Rate N401161 01 4 FB 10 14V dc 0 2 amp 45 or 60 5 flashes minute Contacis silver alloy to silver alloy front and back rated at 5A at 30V dc or 175V ac Power DC power may be from battery or rectified DC current 1 2 SM 9080 Rev 1 July 2011 N 7 AnsaldoSTS 1 3 2 Mechanical All PN 250F relays have the following mechanical specifications Dimensions Height 7 1 16 17 93 cm Width 4 15 16 12 64 cm Depth 8 3 8 21 44 cm Operating Temperature Range 40 F 40 C to 185 F 85 C Indexing Refer to Section 2 5 Weight 6 3 4 Ibs Mounting Base One Piece Style N438689 001 Weight 9
27. t on time readings should be between 45 and 55 4 7 Calibration Requirements 4 7 1 Calibration Values Calibration requirements will be met when the relay adjustment values are the same as those given in Table 4 5 After any shop adjustments are made check the calibration values Section 4 6 2 If they are not within the values given in Table 4 5 the relay should not be shipped for in service use 4 8 SM 9080 Rev 1 July 2011 AnsaldoSTS Shop Maintenance OFF e H NORMAL G 1653 Cf UPPER CONTACT GE REVERSE LOWER CONTACT 9 o A M1 SUPPLY v UNDER TEST COUNTER A Figure 4 4 Flasher Relay Test Circuit 4 8 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 resistances should not exceed the following value Silver Alloy to Silver Alloy 0 03 ohms 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 Section 4 2 1 or 4 2 2 Table 4 4 Mechanical Adjustments and Hold Down Torque Adjusting S Ann Air Arm Min Hold using SPA Relay Gap a Stroke Down Front Contacts Rear Contacts in Grams Cl
28. the rack All wiring terminates at the rear of the mounting base to solderless receptacle contact springs The flash rate is selected as described in Section 2 3 Mounting base details are shown in Figure 5 1 2 3 Flash Rate The flash rate is selectable for either 45 or 60 flashes per minute The relay when plugged into an existing PF 256 circuit will flash at 60 flashes per minute The rate can be easily changed to 45 flashes per minute by installing a jumper on the rear of the existing relay base Two 7 inch jumpers are included with each relay One jumper will be terminated with old style receptacles and the other will be terminated with new style receptacles The type of relay base installed old style Bakelite N384243 or new style M438689 001 will determine which jumper to use The jumper for the old style base is installed between B and B and the new style base would between 2A and 2F Without the jumper the flash rate is 60 flashes per minute 2 4 Electrical The PN 250F relay coil has ordinary pick up and drop away values as any standard biased relay To check the electrical calibration values there is a connection that bypasses the internal flasher module so the electrical values can be checked This is the T terminal on the old style base and 1B on the new style base See for calibration values 3 2 2 2 3 2 2 2 The optimum on time rate for the PN 250F is calibrated at 12 V DC 2 5 Indexing The PN 250F is indexed so t
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