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Chicago Transit Authority - Ansaldo STS

1. SHOWN X 451486 GROUP LAYOUT TUNED MINIBOND F 451486 28 TN GR 2802 GROUP 2801PART IDENTIFICATION DRAWING TIES 7 X 9 X 8 6 20 QTY DEC NUM uM arv DEC DESCRIPTION SUB 170 180 11 5 1 00 MINIBONDTUNED eel 10 EA 1 00 3790066 01 SKIDPUMTG BRKT WOOD TIE E 379 006 40 15 EA ER 20 EA me n TE ES 80 lt LZ ER 25 EA 4 00 050324 ISCREW 1 2X4 LAG GALV 38 30 2 00 J 160119 BLT 3 4 10X2 3 4HXHD f Un 35 2 00 J 480304 NUT 3 4 10 HEX H 40 EA 4 00 J 75196 WSHR 3 4 PL FLAT LH ri 45 EA 2 00 475197 WSHR 3 4 SPR LK M E 50 4 00 J 047503 WASHER 1 2 STEEL PLATE 5 2 45 55 4 00 4047783 WASHER 1 2 PL STL LOCK VIEW A 60 4 00 J 048013 NUT 1 2 13UNC 2B HVY 65 EA SCALE 6IN 1FT 70 EA 75 49 80 EA 1 00 85 EA 451486 2801 LAYOUT TUNED MINIBOND F 451486 28
2. 1 1 11 1 1 JENNI ege 1 1 1 3 1 2 1 3 1 Abbreviations and 1 2 1 3 2 Unit 5 1 3 1 33 nem 1 4 1 4 1 5 SPSCIHICATIONS XR ERE ed Ix 1 4 1 5 1 1 4 1 5 2 Electrical E 1 4 15 3 2 A A 1 6 1 5 4 1 6 1 6 Nameplate Data indere eee n ext ha eee Ea anas ea deere dae 1 7 2 INSTALLATION 2 1 2 1 2 1 2 2 Track Layout Drawings iii ne ri fe tee 2 1 2 3 Installation 2 1 231 Track Preparations eere rete ERR Te 2 2 2 3 2 2 2 233 Installation
3. lt 7 AnsaldoSTS Installation SHOWN X 451486 GROUP LAYOUT TUNED MINIBOND F 4514861 30 GR 3002 ITEM GROUP 3001 PART IDENTIFICATIOI DRAWING QTY NUM UM QTY DEC T SUFFIX DESCRIPTION T NUMBERSHEET SUB k 5 EA 1 00 MINIBOND TUNED E ee 1 E 10 EA 2 00 M 451004 6601 BRACKET MTG D 451004 66 15 1 00 M 379006 02 SKID PL MTG 379 06 E 20 EA 4 00 J 050095 172 13 X 1 3 4 HEX STL 1700R180 m 25 EA 40 30 2 00 J 460119 BLT 3 4 10X2 3 4HXHD t NY 35 EA 2 00 J 480304 NUT 3 4 10 HEX k 40 EA 4 00 1475196 WSHR 3 4 PL FLAT f 45 EA 2 00 0 475197 WSHR 3 4 SPR LK TE 50 EA 121 00 J 047503 WASHER 1 2 STEEL PLATE LH zE 55 EA 8 00 047783 WASHER 1 2 PL STL LOCK 45 408530 M A E 60 8 00 048013 NUT 1 2 13UNC 2B HVY SEE VIEW 65 EA ic ee VIEW A vu IEA s j SCALE 6IN 75 EA QOL j 9 EA m id 1 00 85 EA 51486 3001 LAYOUT TUNED MINIBOND F 451486 30 SEE VIEW P pK Q 21 00 90 EA J 050013 1 4 20 5 8 HEX HD SCREW LL dm TRACK 21 00 95 EA 2 047501 1 4 FLAT WASHER amp BOND S 2 00
4. 2 17 Figure 2 9 Minibond Mounting 2 19 Figure 3 1 AF Mini Impedance Bond Basic 3 1 Figure 3 2 Typical Propulsion Current Flow A and seen 3 3 Figure 3 3 Typical Propulsion Current Flow C and D 3 4 Figure 3 4 AF Minibond Circuit 9 3 5 Figure 3 5 General Minibond 3 7 Figure 3 6 Parallel Resonant 3 8 Figure 3 7 Impedance Versus 3 9 Figure 3 8 Reactive Impedance Versus 3 9 Figure 3 9 Impedance Versus Frequency Three Circuits 3 10 Figure 3 10 Circuit View from One Resonant Circuit seen 3 10 Figure 3 11 Impedance Reflected to Cable 3 11 Figure 4 1 Data 4 5 Figure 4 2 Minibond Test ClrcUit 4 7 Figure 4 3 Connections for L amp 4 8 Figure 4 4 Minibond Schematic 4 9 Figure 4 5 Minibond Schematic Group
5. 4 10 Figure 4 6 Basic Tuning rot tete yo erm utc edit erba eda 4 11 Figure 4 7 Multiple Resonant 4 12 Figure 4 8 Minibond with Three Tuned Circuits Two contain four capacitor banks each 4 14 Figure 4 9 Connections of Capacitor 4 15 Figure 4 10 Capacitor PCB Circuit 4 19 Figure 4 11 Tuning Circuit Test 0 4 22 Figure 4 12 Tuning Circuit Test Set Up and Mother Board 4 23 Figure 4 13 Motherboard Circuit Diagrams essem nennen 4 25 Figure 4 14 Impedance Measuring Test 4 30 Figure 5 1 Part Location Diagram Tuned Minibond Assembly Sheet 1 072 5 3 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Table of Contents Figure 5 2 Part Location Diagram Tuned Minibond Assembly Sheet 2 2 5 4 Figure 5 3 Component Parts Layout Motherboard Printed Circuit 5 5 Figure 5 4 Component Parts Layout Capacitor Printed Circuit 5 8 List of Tables Table 1 1 Tuned Minibond Type Function Frequency Grou
6. JOINTLESS TRACK CIRCUIT STRUCTURE OR SUBSTATION IF APPLICABLE SM 9293 Rev 4 January 2013 MINIBOND INSULATED JOINT TRACK CIRCUIT INSULATED INSULATED JOINT RETURN __ TRACK RAIL CIRCUIT DOUBLE TO SINGLE RAIL TRACK CIRCUIT Installation MINIBOND INSULATED CLS JOINT 7 CIRCUIT INSULATED JOINTS INSULATED JOINT D TRACK CIRCUIT MINIBOND DOUBLE TO DOUBLE RAIL TRACK CIRCUIT WITH INSULATED JOINTS Figure 2 3 Typical Minibond Application Mounted Inside Rails Installation 77 AnsaldoSTS AV 747 AnsaldoSTS SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation MINIBOND SUBSTATION MINIBOND 5 ____ 51 52 OF EACH BOND CONNECTED IN SERIES Figure 2 4 Double Bond Jointless AF track Circuit SM 9293 Rev 4 January 2013 2 9 Installation 77 AnsaldoSTS 77 AnsaldoSTS 2 10 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation
7. R8 WARNING POSSIBLE HIGH 250 C VOLTAGE ss zo evel 46 42 J45 J14 J13 0 J25 J24 J23 422 R13 i N 8H in TRACK RCVR2 TL4 _ TL3 TL2 _TL1 ON 3370 28200 GRP B 94 9 o R28 2820 3370 3900 7 GRP B 3660 3100 2580 T m 2580 3100 3660 GRP A FREQUENCY SELECTION FREQUENCY SELECTION CUT BUS WIRE SEGMENT 9 3 R27 CUT BUS WIRE SEGMENT EX FOR 1900 OR 2100 HZ i FOR 1900 OR 2100 HZ NO CUT REQUIRED NO CUT REQUIRED 1 J TRACK RECEIVER 1 Jio TL5 TL6 _ TL7 TL8 TT MINIBOND MINIBOND CAPACITOR CAPACITOR CAPACITOR PCB PCB PCB GRP A N451657 5203 GRP 451657 5201 451657 5210 451657 5212 451657 5211 WARNING FREQUENCY SELECTION CUT POSSIBLE BUSS WIRE SEGMENT REDUCE POWER BEFORE FOR 2100 HZ OR 1900 HZ NO CUT REQUIRED HANDEING PCB USE INSULATED TOOLS Figure 4 12 Tuning Circuit Test Set Up and Mother Board Layout SM 9293 Rev 4 January 2013 4 23 Maintenance 77 AnsaldoSTS 4 2 5 Impedance Adjustments 4 2 5 1 General Information The impedance of the tuned minibond is adjusted by use of resistors located on the motherboard Each function TT Cab and TR has a group of resistors The resistors in each group are connected in series to increase or decrease ohmic value See Figure 4 13
8. 747 AnsaldoSTS Copyright 2013 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 5 9293 AF Track Circuit Tuned Minibond US amp S Part No N451003 2008 Group A N451003 2010 Group B Installation Maintenance Field Service SM 9293 Rev 4 January 2013 77 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 warranti
9. Track Track xd Resistors Adjustin hm Temp Test Function Fr Test Circuit Lead Temp Test Being Vz Positions Rec Trans Ohms Resistor Adjusted Value Tol Value Tol Meter Meter Freq Freq Across volts volts Scope Scope Hz Hz 21 Hz 5 j R v RZ v R v RZ v TT 1900 5 486 1 0 50 5 TL1 TL17 3900 1900 R21 TBD R22 0 40 R23 0 40 R24 0 40 TL17 TL18 CAB 1 4550 5 3 81 196 1 00 596 TP1 TL12 2820 2820 R1 0 40 R2 0 20 R3 0 10 R4 0 05 R2 0 30 TL11 TL12 TR 1900 0 680 1 0 125 5 TL5 TL10 1900 2820 R13 0 05 R14 0 10 R15 0 20 R16 0 20 R1 0 25 19 110 Note These boards must be set to the proper frequency selection by using temporary jumpers across the appropriate turret lugs Table 4 7 Test Setup Wiring and Impedance Data 4 28 SM 9293 Rev 4 January 2013 727 AnsaldoSTS Maintenance 4 2 6 Final Assembly a Apply Red Glyptal to wire terminal connector screw heads after tightening b Motherboard and capacitor boards should be assembled as one unit prior to inserting the PCBs into the bond Insert printed circuit boards into the bond c Secure motherboard to bond with screws per drawing If the motherboard bows install 8 washers under the motherboard corners d Apply Red Glyptal to screw heads at the corner e Install cover 4 2 7 Final Minibond C
10. g FOR 4 OR 5 CABLE CONNECTIONS SEE APPLICATION DWG D451018 SH 28 Ses ui A ITEMS 165 amp 170 TO BE USED ONLY WHEN CENTER TAP IS REQUIRED 1 EX e J HARDWARE FOR THE MINIBOND CENTER IS SUPPLIED WITH THE MINIBOND 7 CABLES ANCHORED TIES PER INSTALLER DRAWINGS TEMO A REFERENCE FOR PLUG CONNECTOR U S amp S PART NUMBERS STRAIGHT J709146 0292 SOY S8 10 RIGHT ANGLE J709146 0291 REFER TO PART No J709146 0292 STRAIGHT PLUG AND 0291 RIGHT ANGLE FOR fal SOND ED Ad ITEM 110 IS SUPPLIED WITH PLAIN WASHER amp NUT STAINLESS STEEL FOR CABLE CONNECTOR 20 50 55 60 ISOPROPYL ALCOHOL ONLY IS REQUIRED FOR LUBRCATION CONNECTOR CABLE TOOL REFERENCES 5 8 APPROX CRIMP TOOL J709146 0435 285 MIN DIA 610 DIA LOCATORTOOL J709146 0436 D 114 MIN DIA 170 MAX DIA INSERTION TOOL J709146 0437 MOUNTING NOTES EXTRACTION TOOL J709146 0438 GUIDE PIN J709146 0439 TORQUE THE FOUR 13 ELASTIC STOP NUTS CONTACT CRIMP 709146 0434 ITEM 60 TO 15 FOOT POUNDS DO 12 SOCKET NOT OVER TIGHTEN WAYSIDE CABLE APPLICATION NOTES CABLE FROM THE MINIBOND CONNECTOR TO NEARBY JUNCTION BOX 102 0676 00 Figure 2 8 Typical Minibond Mounting to Vagheux Concrete Slab SM 9293 Rev 4 January 2013 2 17 Installation 77 AnsaldoSTS 55 77 AnsaldoSTS SM 9293 Rev 4 Jan
11. gt FREQUENCY Hz Figure 3 7 Impedance Versus Frequency CIRCUIT CIRCUIT 2 oo FREQUENCY Hz Figure 3 8 Reactive Impedance Versus Frequency SM 9293 Rev 4 January 2013 3 9 j Functional Description AnsaldoSTS FREQUENCY Mz 1 BANDWIOTH 8ANDWIDTM SANOWIOTH Figure 3 9 Impedance Versus Frequency Three Circuits in Series TRACK TERMIMALS CABLE TERMINALS Figure 3 10 Circuit View from One Resonant Circuit 3 10 SM 9293 Rev 4 January 2013 v F 7 AnsaldoSTS Functional Description Figure 3 11 Impedance Reflected to Cable Terminal SM 9293 Rev 4 January 2013 3 11 Functional Description 7 AnsaldoSTS 77 AnsaldoSTS 3 12 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance 4 MAINTENANCE 4 1 Field Maintenance and Inspection WARNING To avoid personal injury while maintaining or replacing impedance bonds be sure to disconnect propulsion and signal current in the working area Field maintenance shall consist of periodic visual inspection of the bond for cracks in the housing and bent loosened and corroded terminals Corroded terminals may be cleaned with appropriate abrasive materials and cable lugs re tightened However in the event of case or terminal damage as specified above the complete bond should be returned to the manufacturer All cables should be inspected for possible impact damage or fraying
12. 082 Mfd J709145 0591 15 J709145 0597 47 J709145 0597 47 J709145 0590 1Mfd J709145 0593 33 Mfd J709145 0598 68 Mfd J709145 0590 1 Mfd J709145 0583 01 Mfd J709145 0583 01 Mfd J709145 0592 22 Mfd J709145 0590 1Mfd J709145 0590 1Mfd J709145 0598 68 Mfd J709145 0576 001 Mfd J709145 0576 001 Mfd J709145 0581 0068 Mfd J709145 0578 0022 Mfd J709145 0578 0022 Mfd J709145 0578 0022 Mfd J709145 0582 0082 Mfd J709145 0578 0022 Mfd J709145 0576 001 Mfd J709145 0578 0022 Mfd J709145 0582 0082 Mfd J70945 0580 0047 Mfd J70945 0580 0047 Mfd J70945 0580 0047 Mfd J709145 0583 01 Mfd J709145 0580 0047 Mfd J709145 0577 0015 Mfd J709145 0580 0047 Mfd J709145 0583 01 Mfd J706145 0582 0082 Mfd J706145 0582 0082 Mfd J706145 0582 0082 Mfd J709145 0585 022Mfd 77 AnsaldoSTS J709145 0582 0082 Mfd J7091450579 0033 Mfd J709145 0582 0082 Mfd J709145 0585 022 Mfd J709145 0584 015 Mfd J709145 0584 015 Mfd J709145 0583 01 Mfd J709145 0585 022 Mfd J709145 0585 022 Mfd J709145 0581 0068 Mfd J409145 0586 033 Mfd J409145 0586 033 Mfd J709145 0586 033Mfd J709145 0584 015 Mfd J709145 0588 068 Mfd 5 10 SM 9293 Rev 4 January 2013 my gt 7 AnsaldoSTS Technical Support 6 TECHNICAL SUPPORT 6 1 RAIL Team and Technical Sup
13. 5 amp rating or equivalent set up 1 1 1 1 1 1 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance 4 2 3 Minibond Test NOTE The following tests are made on the minibond with all PCBs removed a Connect the bond in the circuit shown in Figure 4 2 NOTE The leads to the voltmeter should be separated from the other testing leads and connected directly to P1 and P2 b Apply 20 amps DC to the bond and observe the voltage The voltage shall be less than 0 0008 volts Larger values indicate a resistive buildup due to oxidation corrosion etc at the center tap joint at the rail connections Clean the connection surfaces and retest 0 20 Amp DC AMMETER DC POWER SUPPLY 20 A J Figure 4 2 Minibond Test Circuit c Using the circuit of Figure 4 3 measure the series inductance L amp Q values according to the tabulation shown in Table 4 3 Measurements are to be taken at 1000 Hz at a maximum voltage of 1 volt The Dissipation Factor DF may be used instead of Q SM 9293 Rev 4 January 2013 4 7 Maintenance 77 AnsaldoSTS o gt INDUCTANCE TO LEADS BRIDGE UNDER TEST 1 VOLT 1000 Hz SEE TABLE 4 3 Figure 4 3 Connections for L amp Q Values Table 4 3 Minibond Sub Assembly Inductance mH Q Values LEADS FROM BOND CAVITY OR CONN
14. Bed H ERT j M O 9 rp fy TT e 1 m 1 ogo Figure 5 1 Part Location Diagram Tuned Minibond Assembly Sheet 1 of 2 SM 9293 Rev 4 January 2013 5 3 Parts List 77 AnsaldoSTS WIRING TABLE PLUG CONNECTOR TERMINAL NUMBERS AND CORRESPONDING WIRE LEADS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R1 R2 T3 T4 T1 T2 OO SUPPLIED BY OTHERS CAPACITOR PCBs Figure 5 2 Part Location Diagram Tuned Minibond Assembly Sheet 2 of 2 5 4 SM 9293 Rev 4 January 2013 22 v ig 7 AnsaldoSTS Parts List O ISS R5 110 WARNING POSSIBLE HIGH J9 Sf e 059 R1 o lo ze ja le e e NEN ____ e 19 E TL12 Q TL15 501 5960629660956 6506059956605 2 5 R11 1 9 CABITWC 1 TP2 TP3 9 6 o CONN oc us cse cec Wi m RY 6 0 6 6 6 6 6 6 6 6 o
15. Train Detection Track Transmitters and Track Receivers There are eight frequencies divided into two groups used in this function Group A 2100 2580 3100 and 3660 Hz and Group B 1900 2820 3370 and 3900 Hz A bond typically but not always is used to transmit one train detection frequency and receive another train detection frequency This is accomplished by using two parallel resonant circuits The two circuits are referred to as Track Transmitter TT and Track Receiver TR respectively Each circuit is tuned to all four frequencies to facilitate frequency selection by removing a jumper wire The tuning process starts with the highest frequency 3660 Hz for a Group A Minibond because this frequency uses the lowest capacitance value As the groups of capacitors are added together by means of jumper wires TL2 TL7 the tuned frequency is lowered to resonate at 3100 2580 and 2100 Hz All test equipment connections are made to the motherboard per the applicable test wiring and tuning data Table 4 4 Minibonds are to be tuned to each frequency called for in the following order 1 Track Transmitter frequencies TT highest to lowest 2 Cab 3 Track Receiver frequencies TR highest to lowest The capacitor boards and motherboard for a specific minibond part number are married to each other and to the minibond If any printed circuit board is replaced it must be replaced with one having the same part number Tuning should be
16. 100 EA 0 047775 1 4 LOCK WASHER fe pp T 1 00 105 EA 451662 1802_ ANGLE BRACKET F 451662 18 ix ld i A H 2r BRONZE 3 4 PL WASHER N 110 EA 4 00 460120 BOLT ANKR 1 2 13X3 3 4 S 180 Rf SILICONE BRONZE i 115 EA 2 00 J 475121 0115 WASHER 1 2 LK SST d gn A i THE FOLLOWING ITEMS SUPPLIED BY INSTALLER FOR REF ONLY T is lt 150 EA th 1 T 155 P 17 160 nee T 165 CABLE 1000 MCM 21 3 8 170 EA LUG os i AX 175 EA CABLE 500 MCM OR 3 4 10 HEX NUT 180 JEA LUG i i SILICONE BRONZE V E VW BA 185 CABLE 14 VIEW SHOWING APPLICATION 190 EA CONDUIT i 195 EA CLAMP CABLE OF MINIBOND WITHOUT 200 EA CONNEIEIN N CENTER TAP CONNECTION 8 205 CONN TERMINAL PIN SCALE 6IN 210 PADLOCK OPTIONAL 1 1 2 OF BOND TOP OF RAI 1 1 8 BETWEEN TOP GF RAIL amp PLATE 210 9095 10010 165 170 TOP OF RAIL x WE Ss jd 73 i i KE T VE T T T Mx T vk JE a i z a NOTES 2 1 8
17. 12 24 35 38 47 50 GROUPD BCGND ABGND 38T oe 1 R13 R14 R15 R16 9 NN NN J16 05 17004 2 4199 4 420 zb gus 41 44 GROUP A P1 2 O SLOT B N451657 5210 CAB TRANSMITTER 4550Hz 4 T1 TL12 2 LI 1 07mh R1 R2 R3 R4 ANN ANN ANN e ANN 4 o4 J2 2 J3 1 J4 08 45 1900Hz JUMPERS INSTALLED 41 44 14 R25 GROUPA ANN 35 SLOT H 3900 N451657 5212 8 TRACK TRANSMITTER w R26 29 32 GROUPB ANN 4 0 0 a 5570 B 3 R27 GROUPC ANN 1 2 69mh 2820 21 24 35 38 47 50 R28 3 6 GROUPD C ANN TL4 e a 9 12 CDGND BCGND ABGND 26T 721 oS 1 gt 1117 52 PIN B R21 R22 R23 R24 WV e ANY e ANY J21 OPN 122 040 123 4 124 4 425 GROUP MOTHERBOARD N451657 5509 Figure 4 5 Minibond Schematic Group B 4 10 SM 9293 Rev 4 January 2013 727 AnsaldoSTS Maintenance 4 2 4 Minibond Tuning 4 2 4 1 Generalized Tuning Concepts a Tuning a Parallel Resonant Circuit The minibond is tuned by repeating a basic procedure The basic procedure is to tune a parallel resonant circuit to the desired frequency by adding or removing capacitance This is done by injecting the desired frequency into the circuit shown in Figure 4 6 and varying the capacitance until maximum V3 is obtained At the resonant frequency the parallel reson
18. Hz 2580 Hz 2100 Hz 2820 Hz 3100 Hz 2580 Hz 3370 Hz 3660 Hz 3100 Hz 3900 Hz CAB CAB 4550 Hz 4550 Hz DC PROPULSION 3000 AMPS PER RAIL DC PROPULSION 3000 AMPS PER RAIL DC RESISTANCE 00003 OHMS AT 20 C DC RESISTANCE 00003 OHMS AT 20 C UNION SWITCH amp SIGNAL UNION SWITCH amp SIGNAL e 645 RUSSELL ST eo e 645 RUSSELL ST e BATESBURG SC 29006 BATESBURG SC 29006 GROUP A FREQUENCIES GROUP B FREQUENCIES Figure 1 2 Tuned Minibond Nameplate Data Drawing C45166220A SM 9293 Rev 4 January 2013 1 7 General Information 7 AnsaldoSTS 77 AnsaldoSTS 1 8 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation 2 INSTALLATION 2 1 General Installation requirements for an impedance bond are controlled primarily by the physical specifications of user s trackage and associated signal hardware The following remarks and drawings are intended only as a general guide to installation The installer should make whatever adjustments are necessary to insure that a The bonds cables and other pieces are well secured with no possibility of being damaged by low hanging vehicle rigging wheel flanges etc b The section of track outfitted with the bonds maintains standards for tie spacing ballast support etc 2 2 Track Layout Drawings Figure 2 5 through Figure 2 9 provide information for the application of the tuned minibond to 115 Ib RE rail at sites employing the following a Wood ties
19. Limit 5 Group A N451003 2008 F2 2580 Hz 2709 Hz F3 3100 Hz 3255 Hz F4 3660 Hz 3843 Hz F5 1900 Hz 1995 Hz F6 2820 Hz 2961 Hz F7 3370 Hz 3539 Hz 3900 2 4095 Hz Cab 4550Hz 4322 Hz 4778 Hz 4 2 Shop Maintenance 4 2 1 Troubleshooting a Types of Failures 1 Loss of Impedance a Component failure 1 Short 2 Open b Broken wire c Bad or poor connection s 2 Impedance increase 3 Intermittent b Determining the Cause of Failure Information is provided below to assist the user in troubleshooting and repair of the tuned minibond 4 2 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance 1 Sweeping the Frequency to Find Peaks Prior to performing any repair it is suggested that the bond be swept through the audio range to determine probable faults and to isolate the problem to a specific area A source voltage is applied and then the frequency is swept through the audio frequency range Voltage peaks across the wayside terminals or the track terminals are noted These peaks should occur at or near the tuning frequencies of the bonds There should be three peaks refer to Section 4 1 1 for the procedure for minibonds that have at least one jumper cut selecting the transmit and receive frequencies New minibonds will have only two peaks one near 2100 Hz suffix 2008 or 1900 Hz suffix 2010 and the other near 4550 Hz refer to Section 4 2 7 for the procedure The absence of all p
20. M 047503 WASHER 1 2 STEEL PLATE 190 185 4 WASHER 1 2 PL STL LOCK VI EW A NUT 1 2 13UNC 2B HVY SEE VIEW A l SCALE 6IN 1FT 11 2 5 X 451486 LAYOUT TUNED MINIBOND F 451486 31 J p50013 1 4 20 5 8 HEX HD SCRE SEE VIEW B t 3 4 10 X 2 3 4 HEX BOLT 7047501 1 4 FLAT WASHER os SILICONE BRONZE 3 4 PL WASHER 7047775 114 LOCK WASHER E TRACK amp BOND SILICONE BRONZE 98 A 451662 1802 ANGLE BRACKET 451662 18 y on 1 0 4 00 J 460120 BOLT ANKR 1 2 13 3 3 4 AZ d NI 475121 WASHER 1 2 LK SST Zi TT T T 9 THEE 1 175 3 4 LK WASHER SILICONE BRONZE CABLE 1000 a 205 3 4 10 HEX NUT LUG ee ES SILICONE BRONZE CABLE 2500 7 CABLE 14 AF CONDUIT VIEW A CLAMP CABLE L VIEW SHOWING APPLICATION 6 CONN PIN OF MINIBOND WITHOUT TERMINALPIN pum CENTER TAP CONNECTION mE OPTIONAL pe SCALE GIN 7 210 90 951001105 NOTES S B SILICON BRONZE 1 PARTS SHOWN IN FULL LINES TO BE FURNISHED BY US amp S OR INSTALLER TOP OR RAIL A 115 RE RAIL VAGHEUX CONCRETE TIES TYPICAL MTG vl MINIBOND ITEM 5 BE ORDERED BY SYSTEMS ENG R LSS DoS PER G O REQUIREMENTS SEE DWG F451003 SH 20 FOR PART NO S TU 74 A E
21. Minibond hdd an e e Rd en ERA Re Le RARE a nna 4 29 5 PARTS 2 5 1 SM 9293 Rev 4 January 2013 iii Table of Contents 7 AnsaldoSTS 51 General piter ia Co 5 1 6 TECHNICAL SUPPORT itia deben diae xou 6 1 6 1 RAIL Team and Technical 6 1 List of Figures Figure 1 1 AF Tuned 1 2 Figure 1 2 Tuned Minibond Nameplate Data Drawing 45166220 1 7 Figure 2 1 Application of Four or Five Hole T Plate Connector to J 2 3 Figure 2 2 Typical Minibond Application Mounted Outside 2 5 Figure 2 3 Typical Minibond Application Mounted Inside 2 7 Figure 2 4 Double Bond Jointless AF track 2 9 Figure 2 5 Typical Minibond Mounting to Wood 2 11 Figure 2 6 Typical Minibond Mounting to Concrete 08 2 13 Figure 2 7 Typical Minibond Mounting to Floating Concrete 2 15 Figure 2 8 Typical Minibond Mounting to Vagheux Concrete
22. SILICON BRONZE e T T 1 PARTS SHOWN IN FULL LINES TO BE FURNISHED BY US amp S OR INSTALLER A 115 RE RAIL FLOATING CONCRETE SLAB amp 14 AWG STRANDED TWISTED PAIR DIRECT FIXATION TYPICAL MOUNTING cc MINIBOND ITEM 5 BE ORDERED BY SYSTEMS ENG R REFER TO PART No J709146 0292 STRAIGHT PLUG PER G O REQUIREMENTS SEE DWG F451003 SH 20 FOR PART NO S AND 0291 RIGHT ANGLE FOR REFERENCES A FOR CABLE CONNECTOR a FOR 4 OR 5 CABLE CONNECTIONS SEE APPLICATION DWG D451018 SH 28 19 9 ISOPROPYL ALCOHOL ONIS REQUIRED B 5 8 APPROX ITEMS 165 amp 170 TO BE USED ONLY WHEN CENTER TAP IS REQUIRED C 285 MIN DIA 610 MAX DIA CONNECTOR CABLE TOOL REFERENCES D 114 MIN DIA 170 MAX DIA HARDWARE FOR THE MINIBOND CENTER IS SUPPLIED WITH THE MINIBOND MOUNTING NOTES CT 1109146 0435 7 CABLES ANCHORED TIES PER INSTALLER DRAWINGS TORQUE THE FOUR 7 13 ELASTIC STOP NUTS INSERTION TOOL 709146 0437 REFERENCE FOR PLUG CONNECTOR U S amp S PART NUMBERS ITEM 69 15 FOOT POUNDS DO EXTRACTION TOOL J709146 0438 STRAIGHT J709146 0292 NOT OVER TIGHTEN 006068 12 SOCKET A ITEM 110 IS SUPPLIED WITH PLAIN WASHER amp NUT STAINLESS STEEL WAYSIDE CABLE APPLICATION NOTES CABLE FROM THE MINIBOND CONNECTOR TO NEARBY JUNCTION BOX 1D2 0675 00 Figure 2 7 Typical Minibond Mounting to Floating Concrete Slab SM 9293 Rev 4 January 2013 2 15 Installati
23. checked and verified for the particular function or functions Whenever a capacitor is replaced or repairs are made to a capacitor PCB broken wire solder connection etc the tuning should be checked and verified for the particular function or functions SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance 4 2 4 3 Tuning Procedure NOTE Refer to Figure 4 10 for typical capacitor board circuit diagrams Make sure that Section 4 2 4 1 and 4 2 4 2 are read before proceeding with the following procedures a Connect test equipment in accordance with the test circuit shown in Figure 4 11 The 0 1 Mfd test capacitor must be connected across connector terminals b Refer to the appropriate test setup and tuning data table for the minibond being tuned Table 4 4 c Refer to the applicable board suffix d Verify that jumpers are installed across the turret lugs for the designated frequencies of the minibond See Motherboard layout Figure 4 12 NOTE All jumpers above the designated frequency must be in place e Preset track transmitter and track receiver functions jumpers per the tuning data Table 4 4 Set the frequency to the tabulated test frequency shown in the table f Adjust the source voltage to obtain Vtc equal to 1 2 of the tabulated value of Vtc given in the table g Verify proper frequency range as follows 1 Vary the frequency until a voltage peak is obtained 2 Adjust t
24. due to corrosion and replaced if such problems are found Also tightness of various tie hold down screws should be checked to make sure the bond is held securely to the ties 4 1 1 Minibond Operational Check To check that the minibond is tuned correctly or that the proper minibond is installed for the track circuit under test check the minibond as follows a Disconnect the AF track circuit electronics from the minibond under test by opening the appropriate AF rack side straps b Connect the audio oscillator to the field side of that line Connect the oscilloscope and counter in parallel with the oscillator See Table 4 2 for recommended test equipment c Sweep the audio oscillator from 1 7 KHz to 5 0 KHz while watching the scope There will be three peaks These peaks correspond to train detection transmit train detection receive and cab transmit d Record the frequencies at which the peaks occur in the Data Sheet Figure 4 1 Compare these to the allowable frequency range shown in Table 4 1 If the minibond does not operate within the allowable frequency range the minibond must be replaced and returned to the shop for repairs e Remove the oscillator oscilloscope and counter and reconnect the minibond by closing the appropriate AF rack side straps SM 9293 Rev 4 January 2013 4 1 Maintenance 77 AnsaldoSTS Table 4 1 Minibond Allowable Operating Range Nominal Tuned n Lower limit 5 Upper
25. for motherboard circuit diagram Whenever a resistor is replaced or repairs broken wire solder joint etc to the motherboard are made the impedance value of the particular function or functions must be checked and adjusted if required To check the impedance follow steps in Section 4 2 5 2 a through g If adjustment is required refer to steps a through d and 2 1 through g 10 If all functions are to be tested the test shall be done in the order given in the appropriate table Track transmitter and receiver frequencies shall be done at the lowest frequency The 0 1 Mfd test capacitor must be connected across the connector terminals during adjustment 4 2 5 2 Adjustment Procedure NOTE Before adjusting the minibond impedance the minibond must be properly tuned Refer to Section 4 2 4 3 Printed circuit boards are to be assembled in the bond a Connect the test equipment in accordance with the test circuit shown in Figure 4 14 The 0 1 Mfd test capacitor must be placed across the connector terminals b Refer to appropriate test setup wiring and impedance data table for the minibond being adjusted Table 4 6 c Connect leads from test equipment to locations on motherboard as shown in appropriate table d Verify that jumpers are installed across the turret lugs for the designated frequency of the minibond This information is silk screened on the lower corners of the motherboard NOTE All jumpers a
26. k through n If the frequency is too low it will be necessary to remove capacitance from the circuit NOTE Fine tuning capacitor values and their locations on the capacitor printed circuit boards are listed in the wiring table An illustration of capacitor board N451657 52XX is shown in Figure 5 4 4 18 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance CONN1 i C DJMP B CJMP A BJMP CIRCUT DIACRAM Figure 4 10 Capacitor PCB Circuit Diagram SM 9293 Rev 4 January 2013 4 19 Maintenance 77 AnsaldoSTS Part No N451003 2008 Wiring Table for Figure 4 11 and Tuning Data Motherboard 451657 5507 Track Track Fine Tuning Capacitors MFD Temp Test Temp Test se eee tears Test Circuit Lead positions Rec Trans values located in positions slots Resistor Resistor Suffix Freq Tol Vtc Meter Scope Freq Freq Across No Hz volts Hz Hz BANK C7 C6 C5 4 3660 5 24 0 TL1 TL17 3100 3660 A 033 022 010 0068 0033 R5 0 35 TL17 TL18 3100 5 20 3 TL1 TL17 2580 3100 B 015 010 0082 0047 0022 R5 0 35 TL17 TL18 5203 TT 2580 5 16 9 TL1 TL17 2100 2580 C 015 010 0082 0047 0022 R5 0 35 TL17 TL18 2100 5 13 7 TL1 TL17 3660 2100 D 033 015 0082 0047 0022 R5 0 35 TL17 TL18 5210 4550 5 32 0
27. ol D amp 5 R12 100 R17 a a O 20 R24 6 8 se j P 8 4 40 00 a 85 a8 50528 2 R14 J18 TH0 9969 99900000060690000000000 I TL17 525 es 50 MINI BOND MOTHER BD 9 79 49 917 US amp SI E R13 e R21 5 T 9 9 TRACK RECEIVER 1 J16 ps 2 TRACK XMTR RCVR 2 TL5 TL6 117 TL8 1 e Sh DR28 2 3900 NOM TE FREQUENCY SELECTION _ FREQUENCY SELECTION SRPA C CUT BUS WIRE SEGMENT 8 S R27 CUT BUS WIRE SEGMENT uU FOR 1900 OR 2100 HZ FOR 1900 OR 2100 HZ C NO CUT REQUIRED MADE IN USA NO CUT REQUIRED TRACK RECEIVER TRACK TRANSMITTER GROUPA GROUP A F1 2100 Hz NO CUT F1 2100 Hz NO CUT F2 2580 Hz CUT TL7 F2 2580 Hz CUT TL4 F3 3100 Hz CUT TL6 F3 3100 Hz CUT TL3 F4 3660 Hz CUT TL5 F4 3660 Hz CUT TL2 GROUPB GROUP B F5 1900 Hz NO CUT F5 1900 Hz NO CUT F6 2820 Hz CUT TL7 F6 2820 Hz CUT TL4 F7 3370 Hz CUT TL6 F7 3370 Hz CUT TL3 F8 3900 Hz CUT TL5 F8 3900 Hz CUT TL2 Figure 5 3 Component Parts Layout Motherboard Printed Circuit Board SM 9293 Rev 4 January 2013 5 5 Parts List 77 AnsaldoSTS Table 5 3 Parts List for Motherboard PCB N451657 5507 See Figure
28. one of the coil leads and make a DC continuity test across the remaining coil lead and its connection point The test should be applied until a stable reading is obtained since circuit capacitors will draw current until they are charged If continuity exists then one or more capacitors are shorted case c For the remaining cases measure the component values and compare them against what they should be see Table 5 3 and Table 5 5 c Repair of the Determined Failure 1 2 Coil The bond cannot be repaired unless the failure is due to a broken accessible lead Capacitors can be replaced Consult the parts list for capacitor information Table 5 5 Replacement requires a tuning check and possibly an adjustment The larger the capacitor value the more likely an adjustment will be required Resistor s can be replaced Consult the parts list for replacement part numbers Table 5 3 Note the resistance values originally used or else impedance adjustments may be necessary Poor connections should be cleaned and or tightened Broken wires should be replaced SM 9293 Rev 4 January 2013 7 AnsaldoSTS Maintenance Location Test No Revision Page of Minibond pas Minibond Peak Frequencies Hz Comments Track Number Freq F__ Freq F__ Freq Stationing IDEAL Meas IDEAL Meas IDEAL Meas MINIBOND FREQUENCY RANGE
29. sheet for future reference 10 If no further tests remove and store all test equipment 4 26 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Part N451003 2008 Wiring Table for Figure 4 14 and Impedance Data Maintenance Test Conditions Motherboard Nazis Track Track zc Resistors Adjusting ohms Temp Test Freq vesi ele n Ed position R values v Resistor Tes eing Fre Vr Vz Positions Rec Trans Ohms Resistor Adjusted Value Tol Value Tol Meter Meter Freq Freq Across volts volts 5 5 2 2 duds Hz R v R v R v R v TT 2100 5 3 94 1 0 50 5 TL1 TL17 3660 2100 R21 TBD R22 0 40 R23 0 40 R24 0 40 TL17 TL18 CAB 1 4550 5 3 81 1 1 00 5 TP1 TL12 2580 2580 R1 0 40 R2 0 20 R3 0 10 R4 0 05 R2 0 30 TL11 TL12 TR 2100 5 0 543 1 0 125 5 TL5 TL10 2100 2580 R13 0 05 R14 0 10 R15 0 20 R16 0 20 R1 0 25 TL9 TL10 Note These boards must be set to the proper frequency selection by using temporary jumpers across the appropriate turret lugs Table 4 6 Test Setup Wiring and Impedance Data SM 9293 Rev 4 January 2013 4 27 Maintenance 7 AnsaldoSTS Part No N451003 2010 Wiring Table for Figure 4 14 and Impedance Data Test Conditions
30. the minibond impedance is correct If the measured value is outside the range proceed as follows 1 2 Remove jumpers connecting resistors Connect the decade resistance box to the motherboard terminals shown in the table for the function being adjusted Set approximately to the test resistance value shown in Table 4 6 Set the frequency to the tabulated test frequency shown in Table 4 6 Adjust the source voltage to obtain Vr equal to the value of Vr shown in Table 4 6 Measure the voltage Vz and compare it against the tabulated value of Vz If the measured value of Vz is outside the permitted range then vary the value of the decade box to bring it within the permitted range Repeat steps 4 and 5 until the value of Vz is within the permitted range and Vr is within its permitted range This indicates an acceptable impedance value Note the value of resistance on the decade box Remove the decade box from the circuit and place into the circuit that resistance value or the closest value possible This is done by installing buss wire from the turret lugs to the appropriate printed circuit board pads The buss wire is soldered into place It is permissible to short a resistor by installing and soldering buss wire between two pads Buss wire is to be size 18 A W G Verify that Vz is still within its permitted range by repeating steps g4 and g5 Record value of Vz and value of resistance used to adjust circuit on a data
31. 2 00 90 EA J 050013 1 4 20 5 8 HEX HD SCRE SEE 3 4 10 X 2 3 4 HEX BOLT 2 00 95 11047501 4 4 FLAT WASHER VIEW B H SILICONE BRONZE 3 4 PL WASHER 2 00 100 EA __ 047775 1 4 LOCK WASHER lt SILICONE BRONZE 1 00 105 EA _ 451662 1802 ANGLE BRACKET F 451662 18 TRACK amp BON 110 EA lt lt 1 115 20 1 F THE FOLLOWING ITEMS SUPPLIED BY INSTALLER FOR REF ONLY 1 150 EA 3 4 LK WASHER 55 EA SILICONE BRONZE 60 Af 65 CABLE 1000 MCM ee T F 500 565 i SILICONE BRONZE 180 TEA T X T 7 5 85 CABLE 14 AF Ex SEC 90 CONDUIT i xz LY m D i VIEW A 95 EA CLAMP CABLE VIEW SHOWING APPLICATION 8 200 CONN PIN OF MINIBOND WITHOUT 205 CONN TERMINAL PIN CENTER TAP CONNECTION 210 EA PADLOCK OPTIONAL U T U SCALE 6IN 10 1 2 9 TYP 7 8 APPROX OF BOND TO OF RAIL 1 2 BETWEEN OF 168 m RAIL amp PLATE B TOP OF RAIL NOTES S B SILICON BRONZE 1 PARTS SHOWN IN FULL LINES TO BE FURNISHED BY US amp 5 OR INSTALLER UT i T T A 115 RE RAIL WOOD TIES TYPICAL MOUNTING 5 14 AWG STRANDED TWISTED PAIR F REFER TO PART No J709146 0292 STRAIGHT PLUG A MINIBOND ITEM 5 TO BE ORDERED BY SYSTEMS ENG R AND 0291 RIGHT
32. 2 SM 9293 Rev 4 January 2013 ww 7 AnsaldoSTS General Information mV Millivolt PCB Printed Circuit Board p p Peak to Peak rms root mean square method for expressing average AC voltage rating TBD To Be Determined US amp S Union Switch amp Signal 1 3 2 Unit Symbols A Ampere cm centimeter Hz Hertz in inch kg kilogram Ib pound OZ ounce V Volt Q Ohm SM 9293 Rev 4 January 2013 General Information 1 3 3 Definitions CAUTION Reference designator TBD Vte ARNING 1 4 Safety AV 747 AnsaldoSTS Caution statements indicate conditions that could cause damage to equipment An abbreviation assigned to designate an electrical component It generally consists of a capital letter and a number Each letter designates a particular type of component For example C1 identifies a capacitor and R1 identifies a resistor Quality factor of an inductor or capacitor It is the ratio of a component s reactance energy stored to its effective series resistance energy dissipated For a tuned circuit a figure of merit used in bandwidth calculations Q is the ratio of reactive power to resistive power in a tuned circuit To Be Determined Component value determination procedure Voltage across Meter Scope amp Meter Scope test points Warning statements indicate conditions that could cause physical harm serious injury or loss of life Read and thoroughly understand this manual before attemptin
33. 3 Rev 4 January 2013 V Table of Contents 7 AnsaldoSTS 77 AnsaldoSTS vi SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS General Information 1 GENERAL INFORMATION 1 1 Introduction This service manual provides the description installation and maintenance information for the Tuned Minibonds Figure 1 1 used in an Automatic Train Control System The minibond is a multifunction assembly used in cab signaling and train detection applications 1 2 Description The Tuned Minibond is a transformer consisting of a center tapped primary winding and three sets of secondary windings The primary winding is connected rail to rail and serves two purposes to balance the propulsion currents carried by the two rails and to couple the AF train detection and cab signals to the rails Each of the three secondary winding sets is tuned to a different resonant frequency one set is tuned to the cab signaling frequency the second set is tuned to the train detection transmitter frequency and the third set is tuned to the train detection receiver frequency Normally the bond is applied as a track transmitter receiver it can also be used as a dual track receiver However the bond cannot be used as a dual transmitter because the receiver circuit was not designed to be operated as a transmitter The train detection transmitter and receiver secondary winding sets are each capable of being tuned to one of the four available
34. 3 4 10 X 2 34 HEX HEAD BOLT J460119 14 OR 16 3 4 PLAIN FLAT WASHER 475196 SILICON 7 OR 8 3 4 SPRING LOCK WASHER J475197 BHONZE 7 OR 8 344 10 HEX NUT 2480304 HARDWARE X 4 500 MCM 4 LUG FOR 500 2 COPPPER J BAR 0792892 0451004 SH 47 1 4 HOLE T PLATE CONNECTOR 1M451004 7301 4 OR 5 LUG FOR 250 CABLE 1 SHOLE T PLATE CONNECTOR M451004 7302 4 OR 5 750 MCM CABLE Figure 2 1 Application of Four or Five Hole T Plate Connector to J Bar SM 9293 Rev 4 January 2013 2 3 Installation 77 AnsaldoSTS 77 AnsaldoSTS 2 4 SM 9293 Rev 4 January 2013 77 AnsaldoSTS LY JOINTLESS MINIBOND TO STRUCTURE OR SUBSTATION IF APPLICABLE SM 9293 Rev 4 January 2013 fe INSULATED MINIBOND oJ TRE 57 w CIRCUIT INSULATED JOINTS INSULATED JOINT TRACK CIRCUIT DOUBLE TO SINGLE RAIL TRACK CIRCUIT Installation M INSULATED MINIBOND o EACH J w CIRCUIT INSULATED JOINTS LY INSULATED JOINT MINIBOND TRACK CIRCUIT DOUBLE TO DOUBLE RAIL TRACK CIRCUIT WITH INSULATED JOINTS Figure 2 2 Typical Minibond Application Mounted Outside Rails 2 5 Installation 77 AnsaldoSTS AV 747 AnsaldoSTS SM 9293 Rev 4 January 2013 77 AnsaldoSTS MINIBOND
35. 451003 20 451662 18 BRACKET MTG 451662 18 2 13 X 1 3 4 HEX STL 170 oR 180 40 ES BLT 3 4 10X2 3 4HXHD DE NUT 3 4 10 HEX T j d 6 ees 1 E T 38 J WSHR 3 4 SPR LK E 1 s WASHER 1 2 STEEL PLATE 190 185 nn 1 y s WASHER 1 2 PL STL LOCK NUT 1 2 13UNC 2B HVY M HII 45 eese VIEW A Dal j SEE VIEW B SCALE 6IN 1FT 1 00 IEA 51486 2901 LAYOUT TUNED MINIBOND F 451486 29 ff K 2 00 M potona 174 20 5 8 HEX HD SCREW 5 a 2 00 EA 1047501 114 FLAT WASHER S 2 00 EA J 047775 174 LOCK WASHER ae T E TRACK A BOND 61 2 1 00 E 1802 ANGLE BRACKET 451662 18 3 4 10 X 2 3 4 HEX BOLT EA SILICONE BRONZE 3 4 PL WASHER 4 pe 5
36. 5 3 5 Reser oZ otm Swat R2 RIS egies 2 Resor 40 ohm 10 wat RI reque gt Resistor s5 otm swat R27 W 18 Bare Tinned Cop R17 R20 R25 R28 TL17 TL18 TL11 TL12 1 667 ft required A043179 Table 5 4 Parts List for Motherboard PCB N451657 5509 See Figure 5 3 7751 RIS _ esser 40 onm RT requires restr _ 5 6 SM 9293 Rev 4 January 2013 22 77 AnsaldoSTS Parts List Resistor 1 20 ohm 5 watt R19 required ET 0714 Resistor 40 ohm 5 watt R16 Resistor 40 ohm 5 R16 1 required required 735519 0704 0704 W 18 Bare Tinned Cop R17 R20 R25 R28 043179 TL17 TL18 TL11 TL12 1 667 ft required Table 5 5 Parts List for Capacitor PCB See Figure 5 4 Capacitor PCB Receiver N451657 5201 5211 Capacitor PCB Transmitter N451657 5203 5212 Capacitor PCB Cab N451657 5210 Wire copper tinned bare AWG 18 A043179 A BGND B CGND C DGND Capacitors Refer to Table 5 6 NOTE All capacitor values are inmicrofarads rated at 270 volts AC SM 9293 Rev 4 January 2013 5 7 77 AnsaldoSTS Parts List 0 00 0 QN22 8 7272 QNOS INIM Figure 5 4 Component Parts Layout Capacitor Printed Circuit Board SM 9293 Rev 4 January 2013 5 8 727 AnsaldoSTS
37. ANGLE FOR REFERENCES PER G O REQUIREMENTS SEE DWG F451003 SH 20 FOR PART NO S FOR CABLE CONNECTOR ISOPROPYL ALCOHOL ONLY IS REQUIRED OO 5 EOR LUERCATION A FOR 4 OR 5 CABLE CONNECTIONS SEE APPLICATION DWG D451018 SH 28 6963069 1 4 CONNECTOR CABLE TOOL REFERENCES A ITEMS 165 amp 170 TO BE USED ONLY WHEN CENTER TAP IS REQUIRED B 5 8 APPROX CRIMP TOOL J709146 0435 C 285 MIN DIA 610 MAX DIA MOUNTING NOTES LOCATORTOOL J709146 0436 D 114 MIN DIA 170 MAX DIA INSERTION TOOL J709146 0437 HARDWARE FOR THE MINIBOND CENTER TAP IS SUPPLIED WITH THE MINIBOND OD THE FOUR 13 ELASTIC STOP NUTS EXTRACTION TOOL J709146 0438 ITEM 60 TO 15 FOOT POUNDS DO GUIDE PIN J709146 0439 7 CABLES ANCHORED TO TIES PER INSTALLER DRAWINGS NOT OVER TIGHTEN pod J709146 0434 5 REFERENCE FOR PLUG CONNECTOR 0 5 8 S PART NUMBERS WAYSIDE CABLE APPLICATION NOTES STRAIGHT J709146 0292 RIGHT ANGLE J709146 0291 CABLE FROM THE MINIBOND CONNECTOR TO NEARBY JUNCTION BOX Figure 2 5 Typical Minibond Mounting to Wood Ties SM 9293 Rev 4 January 2013 2 11 Installation 77 AnsaldoSTS 55 77 AnsaldoSTS SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation SHOWN X 451486 GROUP LAYOUT TUNED F 451486 29 GR 2902 ITEM GROUP 2901 IDENTIFICATION DRAWING QTY DEC QTY DEC T NuMBER SUFFIX DESCRIPTION NUMBER SUB 1 00 3 ND U NED
38. CEIVER mg 18 29 32 47 50 eese D Gnd Pu R13 R14 R15 R16 e AAA e AAA AAA e NNV J16 0 05 17 01 18 02 419 04 J20 SLOT 5 41 44 451657 5210 CAB TRANSMITTER 4550Hz CT 1 07mh Group A P2 24T 64T 4 TL12 47 50 e T3 a R1 R2 R3 R4 J1 J2 J3 J4 J5 dives 0 4 0 2 0 1 0 05 JUMPERS i INSTALLED i T2 14 R25 41 44 ANN 42 SLOT H 6 N451657 5203 3600 jump TRACK TRANSMITTER R26 29 32 TL2 1 Group NN 9 1 J 2 69mn 3190 jump 15 15518 0 55 2 2580 C D jump 21 24 35 38 47 50 9 TL4 yd 3 6 Group D 26T 721 B C Gnd A B Gnd 15 TL17 lt 427 427 PIN R21 R22 R23 R24 e VWW 2 21 OPN J22 040 923 04 J24 04 J25 GROUP A MOTHERBOARD N451657 5507 Figure 4 4 Minibond Schematic Group SM 9293 Rev 4 January 2013 4 9 77 AnsaldoSTS TRACK CIRCUIT MINIBOND N451003 2010 1900Hz JUMPERS r INSTALLED 51 R17 41 44 GROUPA ANN 4 78 E SLOT F 3 451657 5211 RECEIVER GROUPB d 5 gt 3 GROUPC PJ
39. ECTOR PINS PARAMETERS RI R2 ore eee 570 zoos ro a Wm 222 222 20 we V Value T Tolerance Refer to the minibond schematic Figure 4 4 and Figure 4 5 for connection references d Breakdown Tests A breakdown or leakage current in excess of one milliampere is cause for rejection of the part 1 Connect jumpers to coils leads to connect R2 to T4 to and T2 to Pin A Apply a 3000 volts 60 Hz one minute breakdown test between Pin A and the primary winding 2 Adda jumper between Pin A and primary terminal P1 Apply 3000 volts 60 Hz one minute breakdown test between primary terminal P2 and one of the 1 2 13 mounting bolts 3 Remove the jumper connections used in steps 1 and 2 Apply a 3000 volts 60 Hz one minute breakdown test between the leads R2 and T3 Repeat the test between the leads T4 and 4 8 SM 9293 Rev 4 January 2013 727 AnsaldoSTS Maintenance AC TRACK CIRCUIT MINIBOND N451003 2008 2100Hz JUMPERS INSTALLED S1 RI 1 m5 R17 41 44 A lt 2 pot SLOT F 0 65 PNA 3660 451657 5201 RE
40. ENCES FOR CABLE CONNECTOR A ISOPROPYL ALCOHOL ONLY IS REQUIRED D AEROX FOR LUBRCATION CONNECTOR CABLE TOOL REFERENCES MOUNTING NOTES CRIMP TOOL J709146 0435 LOCATOR TOOL J709146 0436 gt on n og 285 MIN DIA 610 MAX DIA 114 MIN DIA 170 MAX DIA TORQUE THE FOUR 13 ELASTIC STOP NUTS INSERTION TOOL J709146 0437 ITEM TO 15 FOOT POUNDS DO EXTRACTION TOOL J709146 0438 NOT OV R TIGHTEN GUIDE PIN J709146 0439 CONTACT CRIMP J709146 0434 12 SOCKET WAYSIDE CABLE APPLICATION NOTES CABLE FROM THE MINIBOND CONNECTOR TO NEARBY JUNCTION BOX 1 2 0674 00 Figure 2 6 Typical Minibond Mounting to Concrete Ties SM 9293 Rev 4 January 2013 2 13 Installation 77 AnsaldoSTS 55 77 AnsaldoSTS SM 9293 Rev 4 January 2013
41. IGHTEN 3 4 10 X 2 3 4 HEX BOLT 1 SILICONE BRONZE 3 4 PLATE WASHER T SILICONE BRONZE 1D lt NX LOCK WASHER P lt SILICONE BRONZE 3 4 10 HEX NUT 3 4 PLATE WASHER SILICONE BRONZE SILICONE BRONZE E ENLARGED SECTION B A VIEW SHOWING APPLICATION OF MINIBOND WITHOUT CENTER TAP CONNECTION TORQUE NUTS ITEM 4 SO THAT THE INSULATION PAD ITEM 2 DOES NOT COMPRESS MORE THAN 1 5MM 0 059 IN SEE VIEW C TO BE PROVIDED amp INSTALLED A HARDWARE FOR MINIBOND CENTER TAP IS SUPPLIED WITH THE MINIBOND IN THE FIELD BY OTHERS 1D2 0677 00 1 PARTS SHOWN IN FULL LINES TO BE SUPPLIED BY U S amp S INC Figure 2 9 Minibond Mounting Pad SM 9293 Rev 4 January 2013 2 19 Installation 77 AnsaldoSTS 55 77 AnsaldoSTS SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS Functional Description 3 FUNCTIONAL DESCRIPTION 31 Basic Concepts The Tuned Minibond design and application is an extension of the basic concept described below The basic circuit configuration for an audio frequency AF minibond is represented by a primary winding with a center tap and a secondary winding inductively coupled to it see Figure 3 1 The secondary winding may be tuned to increase the impedance of the bond at desired frequencies The center tap divides the primary winding into tw
42. L17 1900 2820 C 015 010 0082 0047 0022 R5 0 35 TL17 TL18 1900 5 12 4 TL1 TL17 3900 1900 D 068 022 022 01 0082 R5 0 35 TL17 TL18 5210 4550 5 32 0 TP1 TL12 2820 2820 A 068 033 015 0082 0047 R2 0 30 TL12 TL11 CAB 3900 5 9 25 TL5 TL10 3900 1900 A 022 0082 0047 0022 0010 R1 0 25 TL10 TL9 3370 5 9 25 TL5 TL10 3370 3900 B 0068 0033 0015 0010 R1 0 25 TL10 TL9 5211 TR 2820 5 9 25 TL5 TL10 2820 3370 C 033 0082 0047 0022 0010 R1 0 25 TL10 TL9 1900 5 9 25 TL5 TL10 1900 2820 D 033 022 01 0082 0068 R1 0 25 TL10 TL9 Note These boards must be set to the proper frequency selection by using temporary jumpers across the appropriate turret lugs Vtc Voltage across Meter Scope amp Meter Scope test points Table 4 5 Test Setup Wiring and Tuning Data SM 9293 Rev 4 January 2013 4 21 v Maintenance 7 AnsaldoSTS TEST CIRCUIT VARIABLE SINE is Tons 10 z 160 W TO BOND 1 PIN A FREQUENCY POWER AMP 16 OHM 1200 OHMS TO COUNTER AUDIO OUTPUT 3000 OHMS AUDIO 190w MAX TO BOND 4S 3P PIN B PIN A IMPEDANCE MATCHING TRANSFORMER POLYPROPYLENE CAPACITOR 0 1 Mfd MINIBOND MOTHERBOARD TEST EQUIPMENT CONNECTIONS Test Positions Per Table 4 4 Figure 4 11 Tuning Circuit Test Set Up 4 22 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance TEMPORARY R2 A TEST RESISTOR
43. Parts List Table 5 6 Capacitor Tabulations N451657 5203 J709145 0593 J709145 0593 J709145 0579 J709145 0581 J709145 0583 J709145 0585 J709145 0586 33 33 0033 Mfd 0068 Mfd 01 Mfd 022 Mfd 033 Mfd J709145 0591 J709145 0590 J709145 0578 J709145 0580 J709145 0582 J709145 0583 J709145 0584 15 Mfd 1 Mfd 0022 Mfd 0047 Mfd 0082 Mfd 01 Mfd 015 Mfd J709145 0593 J709145 0589 J709145 0578 J709145 0580 J709145 0582 J709145 0583 J709145 0584 33 Mfd 082 Mfd 0022 Mfd 0047 Mfd 0082 Mfd 01 Mfd 015 Mfd J709145 0592 J709145 0589 J709145 0576 J709145 0578 J709145 0580 J709145 0582 J709145 0584 22 Mfd 082 Mfd 001 Mfd 0022 Mfd 0047 Mfd 0082 Mfd 015 Mfd J709145 0590 J709145 0585 J709145 0576 J709145 0578 J709145 0580 J709145 0582 1 Mfd 022 Mfd 001 Mfd 0022 Mfd 0047 Mfd 0082 Mfd J709145 0591 J709145 0586 J709145 0578 J709145 0580 J709145 0583 J709145 0584 15 Mfd 033 Mfd 0022 Mfd 0047 Mfd 01 Mfd 015 Mfd J709145 0592 J709145 0590 J709145 0579 J709145 0581 J709145 0583 J709145 0584 22 Mfd 1 Mfd 0033 Mfd 0068 Mfd 01 Mfd 015 Mfd N451657 59210 A J709145 0607 J709145 0587 J709145 0580 J709145 0582 J709145 0584 J709145 0586 J709145 0588 1 0 Mfd 047 Mfd 0047 Mfd 0082 Mfd 015 Mfd 033 Mfd 068 Mfd SM 9293 Rev 4 January 2013 5 9 Parts List N451657 N451657 5212 J709145 0591 15 Mfd J709145 0589
44. RBENT TRANSFORMED VAC SIGNAL TAP AC SIGNAL VOLTAGE CURRENT o AC CURRENT Figure 3 2 Typical Propulsion Current Flow A and B SM 9293 Rev 4 January 2013 3 3 gt Functional Description 7 AnsaldoSTS RAIL 1 DC CURRENT DC CURRENT BALANCING AC CURRENT A CURRENT TOTAL CENTER TRANSFORMED PROPULSION SIGNAL AC SIGNAL CURRENT CURRENT VOLTAGE AC CURRENT Y gt DC CURRENT RAIL 2 C TOTAL RAIL 1 PROPULSION CURRENT AC CURRENT PROPULSION i CURRENT AC CENTER DN TRANSFORMED VAC SIGNAL TAP AC SIGNAL VOLTAGE AC CURRENT Figure 3 3 Typical Propulsion Current Flow C and D 3 4 SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS Functional Description TRANSMITTING RECEIVING EQUIPMENT EQUIPMENT Figure 3 4 AF Minibond Circuit Application 3 2 Design Concepts 3 2 1 General Figure 3 5 illustrates a general schematic of the minibond The minibond is tuned to three frequencies track receiver track transmitter and cab transmitter The track winding is common to all the toroids The high turn winding of each toroid is the inductor of a parallel resonant circuit Each parallel resonant circuit inductor has a core that is independent of the other resonant circuits The track receiver and track transmitter minibonds are actually tuned to four frequencies Only one fre
45. S 1 2100 Hz 1995 2205 F2 2580 Hz 2451 2709 3100 Hz 2945 3255 F4 3660 Hz 3477 3843 F5 1900 Hz 1805 1995 2820 Hz 2679 2961 F7 3370 Hz 3202 3539 8 3900 Hz 3705 4095 Cab Carrier 4550 Hz 4322 4778 Test Technician Date Inspector Date Figure 4 1 Minibond Data Sheet SM 9293 Rev 4 January 2013 4 5 Maintenance 77 AnsaldoSTS 4 2 2 Required Test Equipment Table 4 2 lists the test equipment or equivalent required to perform the tuning and impedance adjustments Table 4 2 Recommended Test Equipment ___ Description __ Manufacturer Quantity 1 Capacitor 0 1 Mfd Commercial Power Amplifier Audio Freq 150 Commercial Oscilloscope Maximum capacitance of 100 picofarads minimum impedance of 1 megohm 10X probe Impedance Bridge Genrad Digibridge Model 1657 Power Supply 20 amps DC Ammeter 0 to 20 amps DC Voltmeter 0 to 0 001 0 0001 volt resolution Test resistors 5 W min 1 Tolerance Commercial 1 2 1 2 2 Voltmeters AC true rms maximum capacitance of 100 picofarads minimum 2 impedance of 1 megohm Various jumpers 18 AWG or larger approx 6 long Jumpers 14 AWG or larger approx 18 long Ends shall be able to clamp to a 3 8 thickness 3 Hy Pot Junior tester 3000 volts rms 60 Hz 1 milliampere sensitivity Decade Resistor Box 0 2 0 ohms 0 05 ohms increments
46. SILICONE BRONZE BOLT LOCATION FOR Lae 33INCH SPACING p lt 175 FH Du BOLT LOCATION FOR T amp 30 INCH SPACING 1 CABLE 1000 MCM 3 4 LK WASHER BIS 4 JA 205 SILICONE BRONZE CABLE SOOMCN 2 ee 2 LS CABLE 14 AF t 4 1 3 4 10 HEX NUT CONDUIT SILICONE BRONZE CLAMP CABLE 8 CONN PIN m CONN TERMINAL PIN VIEW B A PADLOCK OPTIONAL VIEW SHOWING APPLICATION OF MINIBOND WITHOUT CENTER TAP CONNECTION 5 ECC SCALE GIN OR 33 NOTES S B SILICON BRONZE 210 1 PARTS SHOWN IN FULL LINES TO BE FURNISHED BY US amp OR INSTALLER 1188 RE RAIL CONCRETE TIES TYPICAL MOUNTING FOR 30 OR 33 INCH SPACING 30 INCH SPACING SHOWN 155 170 MINIBOND ITEM 5 BE ORDERED BY SYSTEMS ENG R TOP OR RAIL PER 6 REQUIREMENTS SEE DWG F451003 SH 20 FOR PART NO S B k FOR 4 OR 5 CABLE CONNECTIONS SEE APPLICATION DWG D451018 SH 28 2 A ITEMS 165 amp 170 TO BE USED ONLY WHEN CENTER TAP IS REQUIRED IE 6 1 JA HARDWARE FOR THE MINIBOND CENTER IS SUPPLIED WITH THE MINIBOND v 9 2 9 T 7 CABLES ANCHORED TO TIES PER INSTALLER DRAWINGS 74 2 a 8N REFERENCE FOR PLUG CONNECTOR U S amp S PART NUMBERS STRAIGHT J709146 0292 14 AWG STRANDED TWISTED PAIR RIGHT ANGLE J709146 0291 REFER TO PART No J709146 0292 STRAIGHT PLUG AND 0291 RIGHT ANGLE FOR REFER
47. TP1 TL12 2580 2580 A 068 033 015 0082 0047 R2 0 30 TL12 TL11 CAB 3660 5 9 25 TL5 TL10 3660 2100 A 015 0082 0047 0022 R1 0 25 TL10 TL9 3100 5 9 25 TL5 TL10 3100 3660 B 0082 0047 0022 0010 R1 0 25 TL10 TL9 5201 TR 2580 5 9 25 TL5 TL10 2580 3100 C 015 010 0047 0022 R1 0 25 TL10 TL9 2100 5 9 25 TL5 TL10 2100 2580 D 015 010 0068 0033 R1 0 25 TL10 TL9 Note These boards must be set to the proper frequency selection by using temporary jumpers across the appropriate turret lugs Voltage across Meter Scope amp Meter Scope test points Table 4 4 Test Setup Wiring and Tuning Data 4 20 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance Part No N451003 2010 Wiring Table for Figure 4 11 and Tuning Data Motherboard 451657 5509 Track Track Fine Tuning Capacitors MFD Temp Test Temp Test stel eee ares Test Circuit Lead positions Rec Trans values located in positions slots Resistor Resistor Suffix Freq Tol Vtc Meter Scope Freq Freq Across No Hz volts Hz Hz BANK C7 C6 C5 4 3900 5 25 5 TL1 TL17 3370 3900 A 033 015 0082 0047 0022 R5 0 35 TL17 TL18 3370 5 22 0 TL1 TL17 2820 3370 B 015 0082 0047 0022 R5 0 35 TL17 TL18 5212 TT 2820 5 18 4 TL1 T
48. ant circuit has the highest impedance valid approximation for high Q circuit The object of the tuning procedure is to adjust the resonant frequency by varying the capacitance until the resonant frequency equals the desired frequency Once tuned the capacitor s are permanently installed in the tuned circuit Multiple Resonant Frequencies Additional resonant frequencies are obtained by adding more capacitance to the circuit of Figure 4 6 The additional capacitors are connected by jumpers This is illustrated in Figure 4 7 An increase in circuit capacitance will decrease the resonant frequency Each of the capacitors illustrated in Figure 4 7 A could represent a group of capacitors connected in parallel This service manual will refer to such a group of capacitors as a capacitor bank See Figure 4 7 B which shows two banks labeled 1 and 2 The additional bank of capacitors lowers the resonant frequency PARALLEL RESONANT CIRCUIT DESIRED 2 FREQUENCY Figure 4 6 Basic Tuning Circuit SM 9293 Rev 4 January 2013 4 11 Maintenance 77 AnsaldoSTS 4 12 JUMPER ap 2nd DESIRED FREQUENCY podia 2nd DESIRED FREQUENCY Figure 4 7 Multiple Resonant Frequencies Multiple Parallel Resonant Circuits Typically tuned minibonds contain more than one parallel resonant circuit Figure 4 8 illustrates a minibond with three tuned circuits Each capacitor illustrated rep
49. bove the desired frequency must be in place 4 24 SM 9293 Rev 4 January 2013 Maintenance 77 AnsaldoSTS 7 iz ni te _ NI 12 18 E 16 i 12 D 19 1 1 4 4 rS 1 4 been bee 1 4 5 20 Oo amp m 5 amp 5 3 2 bel m 5 aja aja Oo 2 2 oo sls E gg als 5 30 s 9 2 2 6 cleo 518 g 818 E 2 P g 2 _ 2 23 3 3 20 30 RI AAP R5 VM RS dI J0 t 422 R21 R22 R17 TLS TR 421 4 25 315 iagrams 12 itD ircul J3 J14 R10 CIRCUIT DIAGRAM Figure 4 13 Motherboard C 2 R9 SM 9293 Rev 4 January 2013 Maintenance 77 AnsaldoSTS e Set the frequency to the tabulated test frequency shown in Table 4 6 f Adjust the source voltage to obtain Vr equal to the value of Vr shown in Table 4 6 g Measure the voltage Vz and compare it against the tabulated value of Vz If the measured value is within the proper range
50. eaks indicates one or more of the following a broken wire in the bond b loss of connection c track winding shorted d incorrect wiring DC continuity tests can be used to check cases a and b A continuity test can also determine if the track winding is shorted c if the center tap joint is insulated The presence of one or more peaks indicates that the problem lies in the resonant circuits The absence of a peak during a frequency sweep indicates which circuit s causes the problem 2 Impedance Increase Due to the nature of the design in the Tuned Minibonds an increase in impedance can occur in two ways a The Q spoiling resistor of the resonant circuit in question has decreased in value 1 shorted b Component failure of one resonant circuit shifts the tuning of that circuit to a resonant frequency near the resonant frequency of another circuit This type of failure would cause an impedance loss at the original resonant frequency of the circuit shifted SM 9293 Rev 4 January 2013 4 3 e Maintenance 7 AnsaldoSTS 3 Possible Causes for Resonant Impedance Loss Include a Increase in Q spoiling resistor b Poor connections c Shorted capacitor d Open capacitor e Shorted coil f Open coil g Broken wire h Incorrect wiring Disconnect the resonant circuit coil leads and make a continuity test across the coil leads This checks for case f If the coil is not open then connect
51. es 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 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 9293 Rev 4 January 2013 727 AnsaldoSTS Revision History REVISION HISTORY June 2005 Initial Issue Issue Incorporated ECO 140102 1 added Section 1 5 4 November 2005 Environmental Specifications Expanded spec on DC Propulsion Current in Section 1 5 2 Incorporated ECO EE 2092 revised values for C7 capacitor June 2006 for the 5211TR 3900 Hz unit from 033 to 022 Mfd in Tables 4 5 and 5 6 December 2011 Revised Section 1 5 2 Added Figure 2 4 Added Section 2 3 2 added Note to Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 and Figure 2 9 January 2013 ji SM 9293 Rev 4 January 2013 77 AnsaldoSTS Table of Contents Table of Contents 1 GENERAL
52. g any of the procedures listed Pay particular attention to the and CAUTION statements that appear throughout this manual Always observe standard precautions familiar to trained electrical technicians Always adhere to all safety regulations stipulated by the railroad 1 5 Specifications 1 5 1 Physical Dimensions Weight 1 5 2 Electrical 21 W x 6 1 4 H x 12 3 16 D Approximately 65 pounds a All Tuned Minibonds Style Type DC Resistance Current Unbalance AF Mini DC Propulsion 0 00003 10 ohms rail to rail at 20 C 240 ampere turns DC through one turn of the propulsion winding based on the operating characteristics of the AF track circuit system SM 9293 Rev 4 January 2013 7 AnsaldoSTS General Information DC Propulsion Current 3000 amps DC per rail intermittent current rating of 6000 amps DC per rail for 1 minute repeated at 10 minute intervals b Tuned Minibond Impedances and Resonant Frequencies Minibond N451003 2008 see Table 1 1 Table 1 1 Tuned Minibond Type Function Frequency Group A Frequencies mmus Freq Hz Test Voltage Ohms 10 Group A Frequencies Cab 1 Transmitter 4550 1 000 0 500 0 614 Track Transmitter 0 738 0 871 0 125 0 125 Track Receiver 0 125 0 125 c Tuned Minibond Impedances and Resonant frequencies Minibond N451003 2010 see Table 1 2 Table 1 2 Tuned Minibond Type Function Frequency Group B Frequencies me
53. h individual capacitor connected to the resonant circuit The unconnected end can be jumpered into the resonant circuit as required to obtain resonance at the desired frequency value fine tuning This specification will use capacitor decade boxes to determine the amount of capacitance required to fine tune the circuit Appropriate values of capacitance can then be jumpered into the circuit SM 9293 Rev 4 January 2013 4 13 Maintenance 77 AnsaldoSTS BANK BANK BANK BANK BANK BANK BANK Capacitor labels shown are for example only Figure 4 8 Minibond with Three Tuned Circuits Two contain four capacitor banks each 4 14 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance JUMPER TOP VIEW SIDE VIEW A JUMPER Figure 4 9 Connections of Capacitor Banks SM 9293 Rev 4 January 2013 4 15 Maintenance 77 AnsaldoSTS 4 2 4 2 General Information a b Tuned minibonds are tuned to various frequencies The number of tuned frequencies and the frequency values differ depending upon the tuned minibond part number A resonant frequency or a group of resonant frequencies is associated with a particular track circuit function These functions are 1 Cab Transmitters There is one frequency used It is 4550 Hz referred to as Cab 2 Track
54. he source voltage to obtain Vtc equal to the tabulated Vtc given in Table 4 4 3 Repeat steps I and 2 above until voltage peak is obtained at tabulated value of Vtc 4 This frequency shall be within the tabulated tolerance given in the table If not continue with the following steps SM 9293 Rev 4 January 2013 4 17 Maintenance 77 AnsaldoSTS WARNING Possible high voltage Use extreme care when working on the capacitor PCB h Adjust the frequency generator to the desired frequency i Adjust the source voltage to obtain Vtc 1 2 of the tabulated Vtc listed in the wiring table j Using clip leads clip in fine tuning capacitor values on the PCB until a voltage peak 15 found for Vtc the scope or digital voltmeter reading Adjust the source voltage to obtain Vtc equal to the tabulated value of Vtc listed in the table 1 Vary the capacitor value on the PCB by clipping fine tuning capacitors in and out until a voltage peak is found m Turn the power down n Repeat steps k through m until changing the fine tuning capacitors only decreases the voltage Solder a 18 AWG jumper on PCB to connect capacitor s that were chosen in the previous steps Remove clip leads from the circuit o With Vtc set to the tabulated value vary the frequency until a voltage peak is obtained This frequency shall be within the tabulated tolerance listed in the wiring tuning table If necessary repeat steps
55. heck The minibond check shall be performed on the final assembled minibond to verify that it is operating properly a Connect the minibond to the test circuit shown in Figure 4 14 b Initially set the frequency at 1700 20 Hz c Initially set Vr to 0 543 5 volts d Vary the frequency from 1700 Hz to 5000 Hz while looking for voltage peaks Vz across minibond terminals A peak should occur near the tuned frequency of each function listed in the appropriate Wiring and Impedance Data Table Table 4 6 except that only one peak will occur for both track transmitter and receiver since they are tuned to the same frequency NOTE Voltage peaks should occur at the frequencies listed in Table 4 8 Table 4 8 Frequencies for Final Minibond Check Final Check Function and Frequencies Minibond PCB No 451003 Track Transmitter and Receiver Cab 20Hz 50 Hz 2008 2095 4572 2010 1895 4572 SM 9293 Rev 4 January 2013 4 29 Maintenance 77 AnsaldoSTS TEST EQUIPMENT CONNECTIONS To Test Positions Per Table 4 6 TEST CIRCUIT POLYPROPYLENE CAPACITOR SYNTHESIZER FUNCTION GENERATOR MINIBOND MOTHERBOARD IMPEDANCE MATCHING TRANSFORMER Figure 4 14 Impedance Measuring Test Set Up 4 30 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Parts List 5 PARTS LIST 5 1 General Information This section provides parts information for the tuned minibonds Fig
56. n occurs as a result An AC signal is induced into the secondary winding Similarly an AC signal can enter the secondary winding and induce a signal into the primary coil For case C the bond allows the propulsion currents to be re distributed In general this tends to equalize the current in the rails In this application the bond does not benefit from cancellation of the DC current induced magnetic fluxes so the DC unbalance current capacity is reduced The unbalance capacity becomes half of the established rating since current flows through both halves of the propulsion winding In addition the current capacity of the bond is one half of the established unbalance capacity Case D is similar to Case C except that the current flows through one turn instead of two The bond will handle the established unbalanced current rating A typical application of an audio frequency style minibond system is shown in Figure 3 4 The center tap on each bond is shown unconnected but in certain applications the tap may be used for connections to other bonds on the same or adjacent tracks 3 2 SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS Functional Description RAIL 1 DC CURRENT AC CURRENT A PROPULSION 4 CURRENT TOTAL AC CENTER RETURN TRANSFORMED PROPULSION VAC SIGNAL AC SIGNAL CURRENT VOLTAGE CURRENT AC CURRENT RAIL 1 AC CURRENT TOTAL 4 PROPULSION CENTER CU
57. nt end of the cover A two pin connector protrudes from one side of the bond This is where the connection to the wayside equipment is made A nameplate is located on the opposite side Four 1 2 13 x 1 3 8 long studs protrude from the bottom of the bond These studs are welded to the mounting plate mentioned previously These studs are used for mounting the bond during installation Although these studs are sufficient for mounting the bond two threaded inserts are available at the back of the bond to permit fastening down the back end if desired 1 5 4 Environmental Operating Temperature 40 C to 70 C Range Humidity 0 to 95 non condensing 1 6 SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS General Information 1 6 Nameplate Data Figure 1 2 illustrates a typical minibond nameplate All applicable data is stamped on the nameplate for that specific bond eo WARNING POSSIBLE HIGH VOLTAGE e WARNING POSSIBLE HIGH VOLTAGE TO AVOID PERSONAL INJURY WHILE TO AVOID PERSONAL INJURY WHILE MAINTAINING OR REPLACING MINIBOND MAINTAINING OR REPLACING MINIBOND DISCONNECT PROPULSION AND SIGNAL DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA CURRENT IN THE WORKING AREA MINIBOND MINIBOND PIECE NO N451003 2008 SPEC EU 7084 PIECENO N451003 2010 SPEC EU 7084 SERIAL NO SERIAL NO OPERATING FREQUENCIES OPERATING FREQUENCIES TRACK TRACK TRACK TRACK TRANS REC TRANS REC 2100 Hz 3660 Hz 1900 Hz 3900
58. o sections having an equal number of turns Ideally the DC resistance of each section would be the same The primary winding carries the propulsion current so it is constructed with heavy copper CENTER TAP RAIL 2 RAIL 1 Figure 3 1 AF Mini Impedance Bond Basic Circuit Typically propulsion current can flow through the bond in four ways Other variations exist 1 Enters from both rails and exits at the center tap see Figure 3 2 A 2 Enters from the center tap and exits at both rails see Figure 3 2 B 3 Enters at one rail and exits at the other rail Usually the center tap would not be used see Figure 3 3 C 4 Enters at one rail and exits at the center tap or vice versa see Figure 3 3 D SM 9293 Rev 4 January 2013 3 1 5 Functional Description 7 AnsaldoSTS For cases A and the total DC propulsion current flow is divided between the two halves of the primary winding The current direction in one half will be opposite the current direction of the other half The magnetic fluxes induced in the magnetic core of the bond will oppose each other and will therefore tend to cancel each other Equal currents balanced will cancel completely An excessively large current if unbalanced will cause a loss in the AC signaling impedance The signaling current AC enters through one rail and exits through the other rail It transverses the whole winding in one direction and no AC flux cancellatio
59. of Cables scdccctanceccessacnanthaacecdeveqacanenacsaceevsaanndsnadeaccevaaudeadhaadacdevsaadendbatende 2 2 2 9 4 Cable tette 2 2 3 FUNCTIONAL DESCRIPTION R dinaa Reanna 3 1 31 BASIC CONCEDES eased Mereside 3 1 3 2 Design 3 5 3 21 3 5 3 2 2 Bond Impedance Across the Track 3 5 3 2 3 High Parallel Resonant 3 6 4 MAINTENANCE 4 1 4 1 Field Maintenance and 4 1 4 1 1 Minibond Operational 4 1 4 2 Shop 4 2 4 21 Troubleshiootl g icr n rne Eten dave 4 2 4 2 2 Required Test enne 4 6 4 2 3 Minibond Test etre eed ene RISE 4 7 4 2 4 Minibond Tuning eric Rae Ree 4 11 4 2 5 Impedance 4 24 4 2 6 Final Assembly rit t de 4 29 4 2 7 Final
60. on 77 AnsaldoSTS 55 77 AnsaldoSTS SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation SHOWN X 451486 GROUP LAYOUT TUNED MINIBOND 4514866 31 GR 3102 ITEM GROUP 3101 PART IDENTIFICATIOI DRAWING ae T QTY DEC NUM UM QTY DEC T NUMBER SUFFIX DESCRIPTION T NUMBER SHEET SUB 170 OR 480 Hes 5 EA 1 00 MINIBOND TUNED C 451003 13 10 2 00 451662 1806 BRACKET MTG 451662 18 m 40 1 2 13 X 1 3 4 HEX STL 30 lt 38 f 60119 BLT 3 4 10X2 3 4HX Y 1 13 lu 180304 NU 2 4 0 HEX 475196 WSHR 3 4 PLFLAT 0 N ZEE DD Ls 1 LH A 475197 WSHR 3 4 SPR LK E 5
61. opulsion and signal current in the working area 2 3 1 Track Preparations Using the appropriate installation drawing see Figure 2 2 and Figure 2 3 for the impedance bond reposition and refashion the ties as needed to meet basic mounting requirements for the unit and any auxiliary pieces such as a protective ramp Use the application drawing to locate hold down screw holes for the bond and other pieces 2 3 2 Minibond Mounting The minibond is secured to the mounting bracket with four 1 2 13 elastic stop nuts When installing these nuts torque them to 15 foot pounds Do not over tighten the nuts 2 3 3 Installation of Cables Bond to bond cables are prepared according to the basic distance between bond units and special requirements such as crossbonding to other tracks Propulsion cables should be prepared with length sufficient to take up rail running motion Have the ties support the cable as much as possible and secure the cable to the tie so that only the outward end absorbs rail movements 2 3 4 Cable Connections See Figure 2 1 for connection applications The minibond J bar has plated terminals Propulsion cable lugs should also be plated or tinned Corrosion at the bond terminal connections can be reduced by coating the connecting surfaces with a corrosion preventative type of oil or grease A conductive type is recommended 2 2 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Installation 7 OR B
62. p A Frequencies 1 5 Table 1 2 Tuned Minibond Type Function Frequency Group B Frequencies 1 5 Table 4 1 Minibond Allowable Operating 4 2 Table 4 2 Recommended Test 00 00 4 6 Table 4 3 Sub Assembly Inductance mH Q 4 8 Table 4 4 Test Setup Wiring and Tuning Data 4 20 Table 4 5 Test Setup Wiring and Tuning Data 4 21 Table 4 6 Test Setup Wiring and Impedance Data 4 27 Table 4 7 Test Setup Wiring and Impedance Data 4 28 Table 4 8 Frequencies for Final Minibond 4 29 Table 5 1 Parts List for Tuned Minibond Assembly 451003 2008 5 1 Table 5 2 Parts List for Tuned Minibond Assembly N451003 2010 See Figure 5 1 5 2 Table 5 3 Parts List for Motherboard PCB N451657 5507 5 6 Table 5 4 Parts List for Motherboard N451657 5509 5 6 Table 5 5 Parts List for Capacitor PCB See Figure 5 4 5 7 Table 5 6 Capaoltor Tabulations 5 irte e n bat iR Ova e p atta a ee 5 9 SM 929
63. port 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 ansaldo sts us SM 9293 Rev 4 January 2013 6 1 Technical Support 77 AnsaldoSTS 77 AnsaldoSTS End of Manual 6 2 SM 9293 Rev 4 January 2013
64. quency can be used for each at any given time Normally the bond is applied as a track transmitter receiver it can also be used as a dual track receiver However the bond cannot be used as a dual transmitter because the receiver circuit was not designed to be operated as a transmitter 3 2 2 Bond Impedance Across the Track Terminals The inductance of the track winding is around one micro henry The reactance across the track terminals will be very low in the audio frequency range A value of 0 03 ohms would be typical at 5000 Hz The impedance can be increased by tuning the winding Tuning a secondary winding instead of the track winding allows use of smaller capacitors High impedances require high circuit Q s and will only occur near the resonant frequency The minibond has three parallel resonant circuits connected in series The impedance across the track terminals will be the vector sum of the reflected impedances of each resonant circuit The reflected impedances add as in series instead of parallel because induced voltages are proportional to the change in flux through its winding The cores of all the resonant circuits pass through the track winding so the track winding sees a total flux equal to the sum of the individual core fluxes SM 9293 Rev 4 January 2013 3 5 5 Functional Description 7 AnsaldoSTS Current passing through the track winding will cause a voltage drop across the terminals The voltage will be
65. resents a bank of capacitors Each additional bank of capacitors lowers the resonant frequency Four capacitor banks allows a choice of four different frequencies Only one frequency can be chosen at a time for each parallel resonant circuit The customer makes the final frequency selection by disconnecting the appropriate jumper In practice the capacitors illustrated in Figure 4 8 will consist of several capacitors connected in parallel and soldered in place on one or both sides of a printed circuit board Figure 4 9 A illustrates eight capacitor banks with each bank containing four capacitors two on the front side and two on the back side Figure 4 9 B illustrates four capacitor banks with seven capacitors per bank no capacitors on the back side Part numbers 451003 2008 and N451003 2010 contains two circuits with four banks per circuit Single frequency circuits may also be present SM 9293 Rev 4 January 2013 77 AnsaldoSTS Maintenance d Coarse and Fine Tuning Due to tolerances the capacitance required for individual resonant circuits will vary from minibond to minibond The printed circuit boards will contain one or two capacitors which approximate the required capacitance coarse tuning These are permanently installed in the resonant circuit The sum of their values should be less than or equal to the required capacitance Additional smaller values are on the printed circuit boards but they have only one end of eac
66. te Test Voltage Ohms 10 Group B Frequencies Cab Transmitter 4550 1 000 1900 0 450 0 460 2820 0 671 0 681 Track Transmitter 3370 0 802 0 813 3900 0 929 0 941 SM 9293 Rev 4 January 2013 1 5 gt General Information 7 AnsaldoSTS Function Fres He Testvoltage Ohms 107 x 3370 0 125 1 376 3900 0 125 1 592 1 5 3 Mechanical The Tuned Minibond uses Moly Permalloy toroidal cores to construct the coils Each coil has two windings The coils are bound together to form a coil assembly Two J shaped bars of 1 1 4 copper are passed through the window of the coil assembly to form the two turn track winding The coil and core assembly mounting plate receptacle box connector inserts and screws are assembled into a mold The mold is then filled with an epoxy compound and cured The mold forms a cavity at the top back position of the bond Provisions are provided in this cavity for mounting the motherboard and the capacitor PCBs The motherboard contains the resistors used to adjust the impedance of the bond The capacitor PCB contains capacitors used for tuning the board A steel cover with gasket is assembled over the mold cavity It is fastened to the bond with three screws The screw at the back of the bond is recessed inside a steel tube like protrusion A lock can be installed through this tube to block access to the screw A metal catch at the front end of the bond limits travel of the fro
67. that between the resonant peaks some curves are positive and some are negative If these impedances were connected in series they would tend to offset each other 3 6 SM 9293 Rev 4 January 2013 gt 7 AnsaldoSTS Functional Description Track Receiver Circuit Controlling Resistors 14 Twisted Pair Cable Terminals o Two Turns CAB Transmitter Jumpers used for Frequency Selection Track Winding is Common to All Resonant Cores Track Transmitter Circuit Resistor Representing Transformer Core and Winding Resistance Losses Figure 3 5 General Minibond Schematic SM 9293 Rev 4 January 2013 3 7 Functional Description 77 AnsaldoSTS IMPEDANCE VERSUS FREQUENCY TYPICAL HIGH MAGNITUDE 7 5 FREQUENCY Hz BANDWIDTH pe Z R jX X POSITIVE IS INDUCTIVE X NEGATIVE IS CAPACITIVE Note that 1 Z has an inductive component when f f 2 Z has a capacitive component when f gt f 3 Z has no reactance at f fr 4 f 1 2 LC for high 5 At resonance 2 0 L7 R QOL 6 When parallel resonance occurs the loop current sees series resonance 7 0 2 Figure 3 6 Parallel Resonant Circuit REAL PART REACTIVE Z 3 8 SM 9293 Rev 4 January 2013 z 77 AnsaldoSTS Functional Description i be BANDWIUTH BE BANDWIDTH
68. track frequencies see nameplate Figure 1 2 This is accomplished by cutting the proper jumper TL1 thorough TL8 on the minibond motherboard PCB see Figure 5 3 The third secondary winding is tuned to the cab frequency 4550 Hz and is not adjustable SM 9293 Rev 4 January 2013 1 1 General Information 7 AnsaldoSTS Nameplate on side of housing Copper Signal J Bar Rail Cable Connector Connector Motherboard and Capacitor CBs Figure 1 1 AF Tuned Minibond Referring to Figure 3 5 each secondary winding set consists of two windings One of these windings is isolated and capacitively tuned to the appropriate resonant frequency The other winding is connected in series with the equivalent windings from the other secondary winding sets and provides impedance matching to the AF electronics cardfile via a cable connector located on the side of the minibond The impedance of each tuned circuit peaks at its resonant frequency As a result the reflected impedance to the track or wayside at the resonant frequencies will be relatively high Away from the resonant frequencies the reflected impedance to the track or wayside will be low 1 3 Abbreviations Definitions 1 3 1 Abbreviations and Acronyms AC Alternating Current AF Audio Frequency AWG American Wire Gauge CPM Cycles Per Minute CW Continuous Wave dB Decibel DC Direct Current LRU Line Replaceable Unit mA Milliamp msec Millisecond 1
69. transformed to the secondaries The power imparted to each secondary will be determined by the ratio of the secondary reflected impedance to the total reflected impedance The voltage impressed across each secondary will depend on a The secondary reflected impedance b The turns ratio between that secondary and the track winding When the impedance of all the resonant circuits are low the impedance across the track terminals will be low If the impedance of even one of the resonant circuits is high then the impedance across the track winding will be high An exception to this is when two or more high impedance resonant circuits develop a series resonance between them In this case the vector sum of the reflected impedances will be low 3 2 3 High Q Parallel Resonant Circuit The following discussion assumes knowledge of parallel resonant circuit characteristics Figure 3 6 illustrates the general characteristics of a parallel resonant circuit having a high circuit Figure 3 7 and Figure 3 8 illustrate relative impedance characteristics of three high Q parallel resonant circuits having 1 different resonant frequencies and 2 non overlapping bandwidths Refer to Figure 3 7 Note that the impedance at the resonant peaks is much greater than the impedances between the peaks The impedance at a peak of one circuit is much larger than the sum of the magnitudes of the other circuit impedances Refer to Figure 3 8 Note
70. typical mounting Figure 2 5 b Concrete ties 30 or 33 spacing typical mounting 30 shown Figure 2 6 c Floating concrete slab and direct fixation typical mounting Figure 2 7 d Vaghuex concrete ties typical mounting Figure 2 8 e Minibond mounting pad Figure 2 9 Appropriate materials required for the installation or replacement use are listed in the applicable drawings 2 3 Installation Procedures It is necessary to set the minibond to the proper frequencies This can be done in the field but it would be better to pre set the minibond prior to its installation Set minibond frequency by cutting the appropriate buss wire See Figure 5 3 New minibonds are supplied with all jumpers TL2 TL7 installed This sets the track transmitter and track receiver to the same frequency 1900 or 2100 Hz Before connecting the bond to the AF track circuit equipment one jumper must be cut so that the transmitter and receiver are tuned to different frequencies This is done to prevent the AF transmitter from energizing the receiver circuit inside the minibond When using a bond as a single receiver at 1900 or 2100 Hz the transmitter must be tuned to a different frequency by cutting TL2 TL3 or TL4 SM 9293 Rev 4 January 2013 2 1 EY Installation 77 AnsaldoSTS The following paragraphs provide general information on installing minibonds To avoid personal injury while installing impedance bonds be sure to disconnect pr
71. uary 2013 77 AnsaldoSTS Installation TEM GROUP2 GROUP 1 PART IDENTIFICATION DESCRIPTION 1 1 00 1 00 MINIBOND TUNEDLR ________ 451003 20 MINIBON 373030 XX KIT MINIBOND _ 3731 030 GROUH I 2 eaf _ _ 1 373024 01 INSULATION BOND C 373 o29 4 4 00 42001 048162 0010 NUT 1 2 13ELASTSTOPTHINSST 5 eaf 2 00 2 o0 u a6013 19 BOLT3 4 10X23 4HEXHD 6 2 00 2 00 1480304 NUTLS4 OHEX 7 eaf 4 4 00 475196 wasueRs4PLFLAT 8 lea 2 00 2 00 475197 ____ WASHER ____ ____ BE PROVIDED 8 INSTALLED IN THE FIELD BY OTHERS N SEE VIEW A E i j 4 il E ka 7 X MOUNTING PLATE TO BE PROVIDED amp T m h INSTALLED IN THE FIELD BY OTHERS ENLARGED VIEW lt T lt 9 ea ENLARGED VIEW lt s Lane K b MOUNTING NOTES TORQUE THE FOUR 13 ELASTIC STOP NUTS ITEM 4 TO 15 FOOT POUNDS DO NOT OVER T
72. ure 5 1 tabulation lists the major sub assemblies printed circuit boards and miscellaneous hardware and parts The tabulation for lists all the component parts of the motherboard PCBs the tabulation for Figure 5 4 lists all the component parts for the capacitor PCBs To use the parts list identify the part by item number or reference Refer to the tabulation for that item description and part number When using the resistor and capacitor tabulations refer to the column under the applicable printed circuit board part number Table 5 1 Parts List for Tuned Minibond Assembly N451003 2008 See Figure 5 1 ELI eT se Por SST Ne a Ls Screw x 20 x 3 required Washer Plate SST 14 3 required Washer Lock SST 14 3 required Spiral Wrap O D SM 9293 Rev 4 January 2013 5 1 Parts List 77 AnsaldoSTS Table 5 2 Parts List for Tuned Minibond Assembly N451003 2010 See Figure 5 1 ELI 6 Screw Pan Hd SST No 8 32 x 7 16 8 required a Waster tok 6 routed Ls Screw Hex Hd 1 4 x 20 x 1 2 3 required This is an encapsulated subassembly and no attempt should be made to repair it 5 2 SM 9293 Rev 4 January 2013 77 AnsaldoSTS Parts List 4 w 4220 A un didis AM a

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