SERVICE MANUAL 4587 - Ansaldo STS
Contents
1. ee NNN eee eae eee LT LEE IN eS eee RRA NNN sete HERE E BSIGNNHNENNHEMEENEFZGEEESNEENEEEMENEIEEBSEENNNNEE SAREE tt 6 1 6 2 6 3 6 4 6 5 6 6 651 6 8 6 9 7 0 741 Ta 0 02 V DIV mE Voltage to be used during 88 92 pick up test Figure 3 PN 150T Calibration Voltage Conversion Table 4587 p SN 9 10 Q UNION SWITCH amp SIGNAL that the prod will make contact with the center contact heel member which has no terminal finger To make the test with the relay energized and during its pick up interval apply the test prod from the rear of the rack The voltmeter should read in a range from 7 0 to 9 0 volts for relays with a suffix number of 00X The voltage should be in the range of 6 8 to 7 8 volts for relays with 200 and 300 suffix numbers A higher voltage would indicate a conditiion that could be hazardous and the relay should be removed from service Once the relay has picked up the voltage can be expected to go to a lower value that has no significance IX UPDATING THE 001 TO 007 AND 201 TO 208 SUFFIX SERIES RELAY TO 301 TO 308 SUFFIX SERIES RELAYS The 001 to 007 and 201 to 208 suffix series relays can be up dated to correspond2. SERVICE MANUAL 4587 PN 150T TIME ELEMENT RELAY WITH 2F CONTACTS kK kk kk Kk CONTENTS Section Page I GENERAL DESCRIPTION 2 III INSTALLATION AND SERVICE RECOMMENDATIONS 4 IV RELAY OPERATION 4 V RELAY ADJUSTMENTS 5 VI DELAY UNIT DESCRIPTION AND TESTING 5 VII RELAY CALIBRATION 6 VIII SERVICE TESTS 7 8 IX UPDATING THE 001 TO 007 AND 201 TO 207 SUFFIX SERIES RELAY 301 TO 307 SUFFIX SERIES RELAYS 11 X PARTS LIST 15 February 1981 C 2 84 200 127 1 1 UNION SWITCH amp SIGNAL DIVISION PRINTED IN USA AMERICAN STANDARD ING SWISSVALE PA 15218 UNION SWITCH amp SIGNAL I GENERAL This manual is supplied as a guide for operation and mainten ance of the PN 150T relay with suffix numbers of 001 to 007 The manual covers PN 150T relays 201 to 208 and 301 to 308 Table 1 lists the part numbers of the PN 150T s covered by this manual and the corresponding voltage rating and time range of each TABLE l PN 150T RELAYS PART NUMBER VOLTAGE AND TIME RANGE 000 Series N322523 001 N322523 002 N322523 003 N322523 004 N322523 005 N322523 006 N322523 007 200 Series N322523 201 N322523 202 N322523 203 N322523 204 N322523 205 N322523 206 N322523 207 N322523 208 300 Series N322523 301 N322523 302 N322523 303 N322523 304 N322523 305 N322523 306 N322523 307 N322523 308 Volts 10 Time Range 3 30 sec 3 30 sec 3 30 sec 1 2 5
3. J47710 Screw 10 32 x 3 8 Rd N P J51666 Coil See Table III for part No Screw 1 4 20 x 3 4 Cap Stl Tin Pl J50016 Screw 44 40 x 3 16 Rd Hd Stl Tin Pl J525024 Name Plate M433535 Indexing Pin J487090 Gasket J47681 Cover LEXAN M437058 Screw 6 32 x 5 16 Rd Hd Stl Tin P1 J525030 Washer M347631 Screw M321747 Seal Wire J43013 Seal 579351 Calibration Tag 53665 Screw 16 32 x 1 1 4 Fil Hd Stl Mach Tin Pl J52246 4587 p 15 91 peine 8 7 32 REF 2 7 16 REF FOR I2 AND I6 VOLT UNITS ONLY 37 FRONT COVER REMOVED 558 er 38 FOR 10 VOLT UNIT Figure 7 Style PN 150T Time Element Relay Suffix Series 301 to 308 TYNDIS HO LIMS NOINN UNION SWITCH amp SIGNAL ITEN DESCRIPTION WABCO Part 35 Screw M399423 36 Screw Plug M390716 37 Tubing 10 Ins 1 1 8 Long 774030 38 Delay Unit See Table III for part numbers 39 Tag J75828 40 Screw 4 40 x 3 16 Rd Hd F Self Tapping Tin Pl J525024 NOTE Parts bag is shipped with each new relay and is tied to the relay handle The parts bag contains 1 Instruction Tag 1 Nomenclature Tag 1 Indexing Plate 2 44 40 x 3 16 Rd Hd Stl Tin Plate Screws 2 46 32 x 1 1 4 Fil Hd screws 4587 17 4587 p 18 Mounting Base Compl with
4. 312v4d3238 Alddv VYVAONIH YOs gt X CELEC ELEN INDEXING PLATE AND MOUNTING SCREWS FURNISHED WITH RELAY CONTACT SPRINGS ON RELAY 000000 000002 Figure 9 Mounting Base for PN 150T Time Element Relay Suffix Series 201 to 207 JYNDIS 8 HOLIMS NOINN ITM 2 Nuts 1 4 Hd Stl 4597 NOTE B UNION SWITCH amp SIGNAL 20 DESCRIPTION 2 Washers 2 Screws 1 4 20 x 1 1 4 Rda Edy Sekls and Req d Quant Contact Receptacles Solderless J680165 for 14 to 16 wire If other wire size is used request the proper Part Number as shown in Item 1 when ordering base complete i e N399506 except using Contact Receptacles Solderless J680181 Items 5 to 9 inclusive are for attaching mounting base to rack and are contained in the muslin bag shipped with the Mounting Base Complete part number WABCO Part Q UNION SWITCH amp SIGNAL PERIODIC MAINTENANCE All vital relays must be inspected and tested at least every two 2 years The tests and inspections are to include pick up current drop away current timing of slow operating and timing relays visual inspection of contacts for damage or misalignment corrosion or other contamination of parts loose parts inside of cover broken se
5. Rated Input Voltage 0 05 V DIV In the far left vertical column select the appropriate 4 Repeat Step measured zener voltage at the rated input 5 Using the straight edge follow the line across to where Using a straight edge follow the line across to where it intersects the 88 diagonal line it intersects the 92 diagonal line From this point of intersection project down to the bottom of the graph and read the new zener voltage which 6 From this intersection project down to the bottom and read the new zener voltage which will be obtained by once again readjusting the supply voltage the relay will be arrived at by readjusting the supply voltage should NOT pick up 8 8 1 0 A E E L 11 cci E c2 iL eee Ts gg ee er CERIS GE Tr TT ENN LETT ae HH kue LOE ert HH NENENNEMEEEEFZZNEENMENNNNE T Lig p p Eq ES xdg de t M M NOM bern EX JJ TINN NNN FEE EEE ECC CEE ft CE EEC MNNRMSEAMNERMNMEHNSZEARREREFLZGETEEMENPNNERNEPLZSEERSENEWE PET TET ETT eT et eT tT tT Peet ot ET EE E ET TTT TT
6. Solderless Type Receptacle and UNION SWITCH amp SIGNAL PARTS LIST MOUNTING BASE FOR PN 150T TIME ELEMENT RELAYS SUFFIX SERIES 301 TO 308 Reference Figure 9 DESCRIPTION WABCO Part Mounting Hardware N399506 Note A Receptacles Contact Solderless Type for 10 to 12 Wire J680181 Receptacles Contact Solderless Type for 14 to 416 Wire J680165 Receptacles Contact Solderless Type for 18 to 20 Wire J680179 Mounting Base Only N399506 099 Screw 16 32 x 5 8 Fil St Screw 144 40 x 3 16 F Self Tin Pl Washer Not Shown See Note B Screw 1 4 20 x 1 1 4 Rd Stl Tin Pl Not Shown Washer 1 4 Stl Lock M Tin Pl Not Shown Washer 1 4 Stl Plate Tin Pl Not Shown Nut 1 4 Stl Hex Tin Pl Not Shown Meter Test Plug M322965 Insulated Test Plug used for opening any coil or contact circuit and for removing receptacle Springs J077931 When Mounting Base Complete is ordered a muslin bag of Parts 4 1 8 x 5 1 2 is included in che inner carton with mounting base and instruction Prints Bag Contains 2 Tags 4 4 40 scrs x 3 16 Rd Hd Stl T P 2 Lockwashers 1 4 Steel tin Plated 2 Flatwashers 1 4 Hx Hd Stl Tin Plated 6T 8 0 APPLY ABOVE RECEPTACLE SPRING YIM 11nd 9NI Ud
7. min 1 2 5 min 1 2 5 min 1 10 min 1 10 min Some of the 001 to 007 suffix series relays have C terminals on the contact block redesigned electronic delay units The 200 suffix series relays contain The 300 suffix series relays contain delay units with improvements to further in crease reliability for greater reliability Relays N322523 803 and N322523 806 are physically equivalent to N322523 203 and N322523 206 respectively but the former have LEXAN covers COVers II DESCRIPTION All 300 suffix series relays have LEXAN The PN 150T relay is a DC plug in time element relay and has two front or time contacts for external connection It is basically a PN 150B relay with an internal electronic delay unit to determine the relay pick up time relay is furnished for 10 pick up time is adjustable from 3 to 30 seconds for the 30 second relay to 10 minutes for the ten minute relay fixed at 0 5 second for all relays 12 or 16 volt operation The PN 150T The 5 to 5 minutes for the 5 minute relay and 1 The release The power consumption time is varies from 0 5 watts to 2 5 watts depending on the input voltage The PN 150T has two standard silver heel contacts and two silver impregnated carbon front contacts rated at 4 amps and up to 30 VDC or 175 VAC Trademark of General Electric 4587 p 2 Q UNION SWITCH amp SIGNAL TABLE II TEST VALUES Rated Test
8. new delay unit and wire it as shown in Figure 4 being careful to get good solder joints Note that there is no new connection made to the contact finger over which the delay unit sits 3 Calibrate the relay as detailed in Section VII of this manual 4 Reseal the screw heads in the contact block using cement A41225 5 Change first digit of suffix number on nameplate to 2 Figure 4 Wiring for Converted 10 Volt Relays CONVERSION OF 12 AND 16 VOLT RELAYS N322523 002 003 005 006 Conversion of the 12 and 16 volt relays involves replacing both the coil and the delay unit The following procedure outlines the necessary steps 1 Remove the coil from the relay by disconnecting the plug jack connectors 2 Remove the red and black coil wires from the relay by unsoldering them from the contact block 3 Remove the old delay unit by removing the two screws in the contact block and unsoldering the delay unit wires 4587 12 QU UNION SWITCH amp SIGNAL 4 Carefully drill a 6 drill size hole in the relay frame adjacent to the existing hole used for the red and black coil wires Deburr the hole and round the edges using a slightly larger drill 1 4 dia on both sides 5 Place the new coil on the relay frame routing the red and black leads through the original hole and the two white leads through the new hole Lay the excess wire in the open area under the coil Pack the area a
9. the end of the time interval is 92 of the Zener voltage measured at rated input See Figure 3 The relay should pick up Now energize the relay again adjusting the input until the Zener voltage is 88 of that at rated input The relay should not pick up 4587 p 6 UNION SWITCH SIGNAL The pick up calibration is adjusted by slightly bending the support member of the flat bias spring which presses up ward against the bottom of the contact driving member When proper pick up calibration has been obtained the relay should be picked up at the High test voltage given in Table II then the supply voltage gradually reduced until the armature drops away The armature should go to its fully released position at not less than the voltage given in Table II under Min Shop F D When properly adjusted and with the relay deenergized a force of at least 50 grams should be required at the bottom of the contact driving member to lift the armature clear of its full release position The force at the same point to cause center contact to just make should be at least 35 grams As a final test check that the relay will pick up properly at the Low test voltage given in Table II VIII SERVICE TESTS The relay in service should be checked at regular intervals Of perhaps six months for proper pick up time If appreciable wear is observed at the front contacts the release calibration of the relay should be measured Starting with th
10. with the 301 to 307 series relays that have redesigned assemblies to provide a higher overall reli ability The 301 to 307 series are direct replacements for the former relays of the same basic suffix number e g relays with suffix numbers 001 or 201 are replaced with a suffix number 301 relay The delay units for the 301 to 308 series relays are manufactured for three ranges 3 to 30 seconds 1 2 to 5 minutes and 1 to 10 minutes delay units for the 001 007 series were manufactured on a basis of time range and voltage Now only the coils determine the voltage rating for the relay When ordering replacement delay units for the 001 to 007 series for 12 and 16 volt operation it is necessary to order the proper coil so that damage to the delay unit does not occur See Table III for information on ordering items to effect the conversion CONVERSION OF 10 VOLT RELAYS N322523 001 004 007 and N322523 201 204 and 207 The conversion of all 10 volt relays involves changing only the delay unit and recalibrating the relay The following procedure outlines the necessary steps 1 Remove the old delay unit by removing the two Screws on the contact block of the relay and unsoldering the delay unit wires NOTE On some of the suffix 001 004 and 007 relayvs the wire from the delay unit to the C terminal must be cut A wire will not be reconnected to this terminal 4587 p 1l UNION SWITCH amp SIGNAL 2 Install the
11. 6 MAIL ALL ORDERS TO ORDER ENTRY DEPARTMENT UNION SWITCH amp SIGNAL DIVISION AMERICAN STANDARD INC SWISSVALE PA 15218
12. Voltage Min F D A Volts Low High Shop Service 10 8 5 12 5 1 5 1 0 12 10 0 15 0 1 8 14 2 16 13 0 20 0 2 4 l 6 TIME 2F CONTACTS IF gr TRANSISTOR AAA TRIGGER lH DEVICE ZENER O 0 REGULATOR CAPACITORS TERMINALS CIRCUIT FROM REAR OF RELAY VOLTAGE DIVIDER DELAY UNIT RELAY STICK COIL CONTACT Used only on some 001 007 suffix series relays Figure 1 Basic Circuit For All Suffix Series Relays 4587 p 3 UNION SWITCH amp SIGNAL III INSTALLATION AND SERVICE RECOMMENDATIONS The plastic indexing plate furnished with the relay should be applied to the mounting base for the relay using the screws provided To adjust the time interval remove the plug screw from the front of the relay and turn the internal screw with a small screwdriver Clockwise rotation will increase the time The 200 suffix and 300 suffix relays have a timing dial located on the front of the delay unit that indicates the delay time that is the time starting at the application of power to the relay s control circuit and ending with the heels making contact with fronts Accuracy of the timing dial is 10 Accurate time settings are made using stop watch A red light on the front of the delay unit starts to glow the moment power is applied to the relay s control circuit indicating the timing cycle has started Closure between front and heel contacts indicates the end of the timing cycle The red indicator light will con
13. al and cracked or broken cover All vital relays installed in locomotive or car carried equipment are to be inspected and tested at least every two 2 years as above addition every four 4 years the relays are to be removed from service and adjusted repaired and tested Relays not passing the above stated tests and inspections must be replaced and not returned to service until the operating characteristics and conditions in accordance with US amp S Specifications 4587 p 21 UNION SWITCH amp SIGNAL DIVISION HEADQUARTERS American Standard Inc Swissvale PA 15218 412 273 4000 EASTERN OFFICES WESTERN OFFICES ST PAUL 402 McColl Bldg 612 222 7562 OFFICE 5th amp Jackson St Paul MN 55101 SAN 903 Sneath Lane 415 588 6788 FRANCISCO Suite 2300 Or 6789 OFFICE San Bruno CA 94066 PHILADELPHIA 2 Penn Center Plaza 215 568 8032 OFFICE Room 1630 Philadelphia PA 19102 JACKSONVILLE Box 8609 904 724 2607 OFFICE Jacksonville FL 32211 NEW YORK 40 W 40th St 212 840 5438 OFFICE Room 1105 840 5439 New York NY 10018 ST LOUIS 500 Northwest Plaza 314 291 7400 OFFICE Suite 820 St Ann MO 63074 CANADIAN OFFICE MONTREAL 1155 Dorchester 514 866 3677 OFFICE Blvd W Suite 1003 Mont PQ Can H3B 2J2 REGIONAL OFFICES ATLANTA 404 458 5916 ROANOKE OFFICE 703 989 8400 HUNTINGTON OFFICE 304 736 2629 CHICAGO OFFICE 312 759 3577 OMAHA OFFFICE 402 334 151
14. at bias spring mentioned in Section V After energizing the relay apply a slight finger pressure under the armature to hold it in a position with the center front contact just open the delay unit is functioning the relay can now be expected to pick up at the end of the delay period If trouble is traced to the delay unit or the relay coil it is recommended that the entire relay be returned to our factory for correction Several of the electronic components are critical and are selected to provide the proper time range and temperature compensation for a particular production delay unit Therefore these components should be replaced at the factory VII RELAY CALIBRATION It is important to hold the pick up calibration of the relay within specified limits The calibration is kept high enough that if for any reason the transistors should fire too early there will not be enough energy stored in the timing capacitor to pick up the relay the other hand the calibration must be kept low enough that the relay will pick up properly under all service conditions With the voltmeter connected as described in Section VI and set for DC rated input voltage carefully measure the Zener volts toward the end of the delay period The time should be set a MAX of 30 for the 30 second relay and MIN or 1 for the 5 minute or 10 minute relays Now energize the relay again but this time reduce the supply voltage until the Zener voltage at
15. e relay picked up and at full stroke the supply voltage is gradually decreased until the armature drops away and goes to its fully released position If the relay is not fully released at the Service Min F D A value given in Table II herein it should be removed from service Special precaustions have been taken in the design of the PN 150T relay to insure against any decrease in pick up calibration It should therefore be necessary to measure pick up calibration only when the relay is in the signal shop for overhaul The shopping period for this relay can be at least two years regardless of the frequency of operation in service At intervals of about two years a field service check should be made of the integrity of the internal Zener diode regulator circuit as follows The only equipment required is a 0 to 10 VDC or 0 to l5 VDC voltmeter having a resistance of at least 10 000 ohms per volt The instrument should have a test clip on the negative lead and a test prod on the positive lead The test prod should be sharply pointed about 1 16 inch in diameter and at least 2 3 4 inches long The test clip should be attached to negative supply preferably at the relay The prod should be inserted from the rear of the relay rack through the second uppermost center rectangular hole in the relay mounting base Looking at the relay it will be observed 4587 p 7 8 UNION SWITCH amp SIGNAL HOW TO USE FIGURE 3 Zener Voltage At
16. lays N322523 301 N322523 302 N322523 303 N322523 304 N322523 305 N322523 306 N322523 307 N322523 308 10 12 16 10 12 16 10 12 TABLE III 3 30 3 30 3 30 Lj 225 1 2 5 1 2 5 Sec Sec Sec min min min 1 10 min 1 10 min N399531 N399531 001 N399531 002 N399531 N399531 001 N399531 002 N399531 N399531 001 for Red amp Black Wires N437608 001 N437608 001 N437608 001 N437608 002 N437608 002 N437608 002 N437608 003 N437608 003 The existing coil is not changed on 10 volt relays and need not be purchased unless defective on old relay lt 2 2 0 2 gt UNION SWITCH amp SIGNAL i SECTION X PARTS LIST STYLE PN 150T TIME ELEMENT RELAY SUFFIX SERIES 301 to 308 Reference Figure 7 ITEM DESCRIPTION WABCO Part Frame M399420 Latch Rod M388888 Speed Nut J480176 Latch M321728 Dowel Pin J48716 Spring M321861 Armature Complete use Figure 6 amp previous parts list for detail parts N399421 Washer M291657 Screw 46 32 x 7 16 Fil Hd Sh Tin Pl J52243 Contact Block Complete N399434 0001 Tension Washer J475104 Screw 8 32 x 7 8 Rd Hd Stl Mach Tin Pl J52603 Operating Arm M399 422 Permanent Magnet Assembly Magnetized M399444 Strap M321853 Screw 48 32 x 1 1 4 Hed Hd Stl Tin Pl J463078 Bronze Screw M327179 Handle M321821 Lockwasher 410 Int Tooth Ph
17. round the holes with dux seal A41498 to seal the holes 6 Route the wires through the relay as shown in Figure 5 View and B 7 Install the new delay unit and wire as shown in Figure 5 Make the splice between the red and white wire as neatly as possible so that the insulating tubing will slip easily over the joint Per view Check for bad solder joints and short circuits 8 Adjust and calibrate the relay as detailed in Section VII of this manual 9 Seal the delay unit screw leads in the contact block using cement A41225 10 Change first digit of suffix number on nameplate to 2 NOTE The indexing pins on the relay do not change since the 301 to 307 suffix relays are direct replace ments of the former design Conversion Of 12 and 16 Volt Relays N322523 202 203 204 206 208 803 and 806 For conversion of 12 and 16 volt relays with part numbers N322523 202 203 205 206 208 803 806 the procedure will be the same as the above except the coil will not change 4587 p 13 86 vi View A Wiring for White Wires RELAY PART NUMBERS AND CORRESPONDING UP TO DATE COIL AND UP TO DATE DELAY UNIT PART NO 5 N322523 001 N322523 002 N322523 003 N322523 004 N322523 005 N322523 006 N322523 007 Figure 5 N322523 201 N322523 202 N322523 203 N322523 204 N322523 205 N322523 206 N322523 207 N322523 208 View B Wiring Wiring for Converted 12 and 16 Volt Re
18. tinue to glow after closure on front contacts and will only be extinguished when power is removed from the relay s control circuit It is recommended that the relay be checked at regular intervals for proper pick up time and at longer intervals to meet the requirements given in Section VIII The 200 suffix and 300 suffix series relays will operate from 85 to 1255 of rated voltage The suffix 000 series relays can be energized at up to 150 of rated voltage Voltages in excess of these amounts should be avoided as they cause excessive power dissipation that can damage the components within the delay units IV RELAY OPERATION The basic circuit for all suffix series relays is shown in Figure 1 Constant voltage of the zener regulator charges a solid tantalum capacitor bank through an adjustable resistor the charging time being proportional to the resistance setting When the capacitors have charged to a reference voltage determined by the divider resistors a transistor combination is triggered causing the capacitors to discharge through the relay coil resulting pulse picks up the relay which holds itself up over an internal front stick contact until the supply voltage is removed 4587 p 4 5 UNION SWITCH amp SIGNAL 3J V RELAY ADJUSTMENTS The relay armature is set at the factory to a parallel air gap of 0 23 inch The adjustable back stop screw in the horizontal extension of the permanent magnet assembly is adjusted
19. to provide an air gap of 016 inch between the armature and the extension The extension itself is adjusted to provide an armature stroke of 0 110 inch at the main non adjustable stop pin All checks of contact adjustment should be made with the relay in its normal upright position The Time left and right contacts should be adjusted to be barely open with the armature held up against a 031 inch spacer at the main stop pin With a 029 inch spacer these contacts should be closed The center contact should be adjusted to be barely open with a 039 inch spacer at the main stop pin With a 037 inch spacer this contact should be closed Contacts are adjusted by bending slightly at the base of the front contact members The flat bias spring which presses upward against the bottom of the contact driving member should be adjusted as called for in Section VII detailed information on the cleaning and adjustment of contacts is given in Service Manual 455 entitled PN 150B Biased Neutral Plug In Line Relay and Service Manual 4560 Instructions for Cleaning Relay Contacts VI DELAY UNIT DESCRIPTION AND TESTING Delay units supplied with the suffix 000 series relays were selected on the basis of supply voltage and time range In the suffix 200 and 300 series the delay unit is selected on the basis of time only with the relay coil being chosen on the bias of supply voltage See Table III for a complete listing of
20. up to date delay units used on the 300 suffix series and relay coil used on the 200 and 300 suffix series The delay units used on the 000 and 200 series are no longer available For updating relays see Section IX CAUTION It is important that the proper coil be used with the suffix 200 and 300 series delay units Ohterwise complete destruction of the delay unit may occur The magnetic shield can be slipped off the delay unit by re moving two small screws at the front end Connect a 0 to 10 VDC or 0 to 15 VDC voltmeter having a resistance of at least 10 000 ohms per volt from the minus terminal of the relay see 4587 5 UNION SWITCH amp SIGNAL Figure 1 to the two potentiometer terminals which are tied together It will be convenient to set the time ad justment at MAX for a 30 second relay and MIN for a 5 minute and 10 minute relay Apply rated voltage to the relay During the pick up delay period the voltmeter should read in a range from 7 0 to 8 0 volts A higher voltage would indicate a condition that could be hazardous Once the relay has picked up the voltage can be expected to go to a lower value that has no significance The relay pick up time should be measured at MAX then MIN It should be observed that the time is adjustable over the full range of 30 to 300 seconds or 3 to 30 seconds or 1 to l0 minutes If the relay does not pick up it may be that the relay is out of calibration at the fl
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