Sm-4570a

Transcript

ffi. SERVICE MANUAL 4570-A .. MAGNETIC STICK, CODE-FOLLOWING VITAL RELAY PC-250P Part Numbers ! N322SS9- I012 I013 I014 I01& I 01s ! 019 ! THIS MANUAL SUPERCEDES SM4570-A DATED JANUARY, 1982 December, 1986 (Rev. 1/87) 1001200t0N00230 A-2188-50- 1004-2 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC/ PITTSBURGH, PA 15237 ffi. SERVICE MANUAL 4570-A . MAGNETIC STICK, CODE-FOLLOWING VITAL RELAY PC-250P Part Numbers I N322559- I I I 012 013 0141 016 I 018 I 0191 ... THIS MANUAL SUPERCEDES SM4570-A DATED JANUARY, 1982 December, 1986 (Rev. 1/87) ID0120DIDN0023D A-2188-50· 1004-2 UNION SWITCH & SIGNAL DIVISION AMERICAN ST"ANDARD INC/ PITTSBURGH, PA 15237 . --b'::f UNION SWITCH & SIGNAL RE'l!S!Ollf !T\TOE:X This service manual supersedes all previously issued SM4570-~ manuals and has been reissued to provide new or correct@d data. Oe3troy all previously issu~d SM4570-A manuals. Future revisions to this manual will be handled by an addendum, wherein a Revision Index page will be provided, listing alt revised pages. ... PAGE! REV'!SEO A 2 A-1 A-2 l/87 1/87 1/87 1/87 1/87 1/87 1/87 A-4 A-6 A-7 UNION SWITCH & SIGNAL Con tents Section I II GENE.RAJ:. INFORMATION. 1 l. l 1.2 1.3 .l. INT.ROOOC'L'ION. • DESCRIPTION • • SPECIF ICA'.rION S. INSTALLATION 3 2.1 2.2 3 3 J GENERAL ~UNTING BASE • RELAY INDEXING. RECEP'l'ACLE CONTACT SP RlNGS RELAY IN SE.R'rI UN • 2.3 2.4 2.5 rrr 4 6 MAlNTBNANCE •• FIELD 3 .1 IV .J.. l 7/8 3.2 INTROooc·rroN. • • • • • • • PERlUD!C PE.RFORMANCE TESTS. 7/8 7/8 StlOP MAINTENANCE. 9 4.1 INTRODUCTION. CLEAN ING AND INSPEC'rION CHECK-OU'£ PROCEUURES R.EPAI.HS AND REP LACE..'11.E:NT ADJUSTMENTS CALIBRATION CALIBRATION REQU IRE.M.ENTS 4.2 4.3 4.4 4.5 4.6 4.7 APPENDIX A . . ..... ...... ~ 9 ..... 12 12 15 .J..5 .J..7 ?AR':S LIST i ffi UNION SWITCH & SIGNAL. SECTI:)N ! GENERAL INFORMATION !NTROOUCTION This manual provides service information for the PC-250P plug-in relay. The PC-250P relay is a magnetic stick code following relay designed for transmitting •corrected code•. It is operated from a PC-250TR code generating relay and is controlled through its own contacts. This •corrected code• does not change and therefore contact wear on the code generator is compensated or •corrected•. The design of the PC-250P relay conforms to all applicable AAR specifications. 1. 2 OESCRii?TI ON 1. 2 .1 General The PC-250P relay is a magnetic stick relay, in which the armature always remains at full-stroke in its last energized position. When deenergized the relay will be at •Normal• (contacts closed left) if the last applied polarity was as indicated on the mounting base. It will be at •Reverse• (contacts closed right) if the opposite polarity was last applied. The relay is factory calibrated to operate across a wide environmental range. All moving parts are enclosed in a sturdy, transparent, dust and moisture resistant cover. To ensure the relay is inserted in its proper mounting base, tt relays have indexing pins. Relays lock securely into the plug-in position. 1.2 .2 Coils Coil resistances of PC-250P relays are (depending on part number) 180/180 or 20/20 ohms. Refer to paragraph 1.3.l to correlate part numbers to coil resistance values. The resistance selected depends on the system voltage and circuitry. l. 2. 3 con tac ts The PC-250P is made with various combinations of low-voltage silver-platinum and high voltage tungsten contacts. t.v. contacts are indicated by green markings · on the contact post members in the relay, while H.V. contacts are indicated by red markings. 1.3 SPECIFICATIONS ·rhe Eollowing patagtaphs provide the electrical and mechanical s~ecifications of the PC-2SOP code following relays covered in this manual. 4570-A, p. 1 ffi ffi UNION SWITCH & SIGNAL l. 3. l E:lectri.c.J.l Relay electrical speciEications are tabulated below. MIN. MAX. P.O. AMPS P.O. AMPS .v. 180/190 0.011 0.013 8-12V 1( NR) N322559-012 Fi.V'. r{. N322559-0l3 [,. v. t.V. t.V. r..v. 180/180 0 .011 0 .013 8-12V N322559-014 * * t.V. L.V. 20/20 0 .031 0.035 N3 22559-016 r..v. t.V. L. V. t,.V. 20/20 0 .031 0.035 ------- N322559-0lS * L.V. L .V. t.V. 20/20 0.031 0.035 S-12'1 N322559-019 H.V. t.V. t.V. t..V. 20/20 0 .031 0.035 8-12V P.11.RT NO. I COIL RESIS. OHMS CONTAC'rS 2cmu 3 (NR) I 4 (NR) * N = H.V.; R v. Ff. v. Ff APPLICABLE INFORMATION = t..V. Contacts - Two types of contacts are available in the PC-250'? Relays: r..v. and H.V. The r..v. is silver platinum to silver platinum for use in circuits below SO volts. The H.V. is tungsten to tungsten for use in circuits above 50 volts to provide longer contact life. However, the tungsten contacts cannot be employed in low voltage circuits due to th~ contact resistance which they develop. 1.3 .2 Mechanical T~e following mechanical specifications are common to all PC-250P relays covered in t!iis manual. Dimensions: Height Width Depth 7-1/16• (17.93 cm) 4-15/16• (12.54 cm) 8-3/S• (21.2 cm) Temperature I:1dexing: Relay part number determines indexing plate required. (Refer to paragraph 2.3) W,'! il!NG lliEVER DRILL NEW HOLES IN A BA.Sr.! INDEXING Pt.ATE WH!CR WILL PERMIT APPLICATION OF RELAYS WITH DIFFERENT PART lliO~BERS OR CHANGE INDEXI!liG PINS ON THE Ba.CK OF A RELAY ONL~SS IT rs BEING CONVERTED TO A NEW PART lliOMBE~. OTHER 1'1i:SE, A HAZARD WILL BE CREATED WHICH MAY COMPROMISE SA~ETY CIRCUIT FUNCTIONS. 2.4 RECEPTACLE CONTACT SPRINGS 2.4.l Old Style Base Only The N382316 mounting base will normally be equipped with the required quantity of J680165 solderless receptacle contact springs, and will accommodate one or two tl4 or 116 wires. It can, however, be equipped with receptacle contact springs for one or two ilO or 112 wires (J680181), or for one or two 118 or !20 wires (J680179). Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation. 2.4.2 Improved One Piece Base Only The new one piece mounting base with hardware includes a full complement of receptacle contact springs (M451142-2702) to accommodate one or two il4-Jl6 wires, mounting fasteners, and tags. rt can, however, be equipped with receptacle contact springs for one or two JlO-tl2 wires {M45ll42-2701l, or for one oc two tlS-t20 (M45ll42-2701). Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation. Each solderless receptacle contact spring should be inspected for physical damage before proceeding with installation. The following is recommended when installing solderless receptacle contact springs: a. ~eceptacle contact springs must be inserted into the base with the lock side down or lanced tab up (Refer to Figure 2). b. ~ake certain that the lanced tab is slightly compressed as the receptacle contact spring is inserted along the top of the cavity. The lanced tab could have been bent during ~andling, and therefore would not provide the required contact pressure after the relay is insetted. tf the lanced tab does not touch, pull it u9 slightly using fingers or a suitable tool. c. ~fter insertion, pull firmly on the wire to make certain the rece?tacle contact spring is locked in the cavity. 4570-i\, p. 4 UNION SWITCH & SIGNAl. Figure ·1. Typical Plug-ln Relay and Mounting Base RECE?T ACL!: SPRING LOCK SIDE OLD MOUNTING BASE Figure 2. RECEPTACLE ~;;~~~~-V SPRING LOCK SIDE NEW MOUNTING BASE Receptacle Contact Spring lnstalled 4570-A, p. 5 83 UNION SWITCH & SIGNAL 2.4.3 rnst.alling Wices in Rece?tacle contact Springs use the Eollowing ococedure to ensure a good electrical and mechanical connection between the conductor wire and the receptacle contact. spcing. The following table identifies the correct crimping tool to be used when installing wires in receptacle contact. springs. Crimping Tool J397138 J397139 J3qnss 2.5 Wire Size Old Style Receptacle cont.act Sp::ing tl0/U2 AWG tl4/U6 AWG t18/J20 AWG J6801Sl J680165 (Standard) J680179 Improved sase Receptacle cont.act Spring "1451142-2703 M451142-2702 M45l l42-2701 a. Strip 3/16 in. (0.187 in. oc 0.47 cm.) of insulation from the end of the wire. b. Place the receptacle contact spring into the jaws of the peeper crimping tool. When using only one terminal, of any wire size, use the shortest terminal. c. Partially close the crimping tool jaws against. the receptacle contact spring to hold it in place. (Do not crush the receptacle contact spring barrel at this time.) d. rnsert the strip;,ed end of wire all the way into the receptacle contact spring barrel. squeeze the tool handles until crimping is completed and the jaws celease. When using both terminals, it is more convenient to attach the first wire to the longest terminal. e. Remove the crimped receptacle contact spring from the tool and inspect the connection. ~ake certain that the wice is flush with the crimped barrel and that there are no loose strands of wice. RELAY !~SERT!ON Orient the relay to the mounting base with the name plate right side up; then plug the celay into the base. The relay should be pushed firmly against the mounting base while depressing the latch rod. After the relay is completely seated in the base, release the latch rod and pull on the handle to ensure that the relay has locked in place. 4570-.~, p. 6 UNION SWITCH & SIGNAL ffi SECTIUN HI FIELU MAlN'rENANC.S 3 • .!.-- ..cN'l'.t<.OOOC'£lON '1'nJ..s sect.i.on provides tne necessary perioaic preventJ..11e maintenance proceaures wnJ..ch must be performea to ensure continuous, proper, and efticient operacJ..on ot the l?C-2SOP stJJ..e reiays coverea in this manual.. Fie~d maincenance covers perJ..odic 1nspeccions and performance tests. 3. 2 .3. 2 .1 PE.t{llJD!C PER.FUHMANCE ·r.::s·r Cleaning Beiore inspecting ana testing the re.!.ay, if necessary use a soft Cl.Och to CJ..ean tne excer ior co remove any dirt or dust that may have co.!..lectea. A safe c.1.eanin~ solution or a.!..cono.!.. ana water or common .1.aunary aetergenc may be usea for removal. of dCcumu.Latea ~ire, grease, etc. 3.2.2 ServJ..ce Hequirements 3 • 2. 2 .1 Gener a.L Ai.!. vital code reJ..ays must be inspected ana cested at .!.east once each year. The te~ts and inspections are to include: pick-up current, drop-away current ana proper code to.Liowing operation; and Vlsual inspect.ion of contacts foe carnage or mJ..saLignment, corrosion or otner contamination of parts, loose parts insiae ot tne cover, oroKen seal, ~nu cracKea or oroken cover. Heiays not passing the above statea tests and inspections must be rep1acea ana not returnee to ser11ice until cne operating characc~riscJ..cs and condJ..tJ..ons are in accoraance w1th OS&S specifications. 3.2.2.2 In-Service Test It is .cecorrunenaeci that .Line re.Lays in se:::vice be removea t:::om service for sbop repa1rs when the ca.1.ibration 11alues are not within ~~e FIELD LIMITS given in Tao1e r. CAUTION CALIBRATIUN OF ~rlESE RE.LAY::; MUST BE MAJ.)g ElTJ:i.ER lN A NON-M.E:-.1.'ALLlC ::;Utli'ACE. WHEN F I.::OLD ~ESTING WITH COVERS UN, to NOT SET THE RELAYS ON STEEL TA~LE::; OR HUUSE FLOORS. RELAYS MOST ~E SUPPOR·r.i::o ON A NUN-MA~NE'l'IC SiJH.FAC.E. ·r.::s·r S'!AND O.t:l UN A J.2.2.3 T~~t Pruceuures ·rest the operating chacc:1ccec is tics of t!'le PC-250P scyle relays as aescr 1.oea in s~ction 4. b 1.n th lS manua.L. 4570-A, p. 7/'d 'JNION SWITCH&. SIGNAi.. SECT!O"i !V SHOP MAINT!::NANCE -- 4. l INTROOUC~!ON This section ocovides the infocmation necessary to perfocm shop level cepai:s of the PC-250P style relays covered in this manual. In general, celays acriving at the shop foe cepair have been checked in the field and have been found to perfocm unacceptably oc have been physically damaged. 4.2 CLEANING AND INSPECTION Befoce inspecting the celay and initiating repairs, use a soft cloth to clean the exterior carefully to remove any dirt or dust that may have collected. A safe cleaning solution of alcohol and water may be used foe removal of accumulated dirt, grease, etc. Inspect the relay extecioc for signs of physical damage, such as cracked or bcoken cover, cracked or damaged housing, and damaged and or missing contact block terminals and indexing pins. If severe damage is found, a careful inspection of the interior components should be made foe obvious physical damage. Remove the covec and clean the sutface between the armature and the pole faces, especially the stop pin area, using a lint free cloth and alcohol. Proceed with relay contact cleaning, using the following recommended cleaning tecials: Recommended Cleaning Materials Cleaning Tool Extra sleeving for cecovecing three metal strips !4/0 Metallographic paper sheet 9• x 14• surnishing tool Distilled water: 4.2.1 Order: Reference N378099 J772330 J035215 J397187 Cleaning Relay Contacts -This section covecs recommended methods for the preparation and cleaning of relay contacts. After contacts have been dressed and/or after adjustments have been made to meet calibration requirements, the contacts should be cleaned in accordance with the procedure given in pacagraph 4.2.1.1 and 4.2.l.2. Due to the possible unavailability of the sleeving {J772330) foe the cleaning tool (N378099), an alternate contact cleaning procedure is presented in Paragraph 4.2.2. 4570-A, p. 9 ffi UNION SWITCl-i & SIGNAL CAO'.L'!lJN IF IT rs OESIRED TO USE AN AEROSOL SPRAY FOR CLEAN .LNG .t:IBLAY CuNTA\.:TS, ONLY VIKGIN FREON '.r.F (AVAILABLE F&OM MILLE.tt s·rEPH.ENSON C.HE!'iICAL co. AS !>"..S-.J..80 OR MS-230 CONTAC'.L' KE-NU FREON TE') rs APPROVE!) BY US&S. 4. 2 • .L. .L a. G,,mer al Pre.Liminary Information The cleaning tool should be used to c.Lean no more than .i.2 front and 12 back contacts, after which they shoula be washed oefore re-use. Tne c.Leaning tool should be c.Leanea using a mild soap or detergent ana water, rinsl.ng thorougnly and allowing to dry. b. New Sleeving To apply new sleeving to the c.Leaning tooi, heat seal one end oy pl.acing in a flame and pinching quickly with pliers. Stretch the s.Leeving over the cleaning tool and cut off excess material .L/8• oeyond the end of the tool. Keeping t.~e material stretched, heat seal t.~e second end. Wash the tool before using if ic Joes not appear to be perfectiy clean. 4.2.l.2 Contact C.Leaning Procedure a. Apply aisti.Lled water (dispensed from a c.J..ean c.J..osed container) to a c.Lean cleaning tool, ana wash the silver/platinum (green) contact tip memoers while applying pressure by ho.Laing the cont.act mounting biocK. Wipe the contacts with at least six short stroKes of the too.L. o. Immediate.Ly after the washing, the contacts should be wipea ary using a secona clean, lint-free c.Leaning tool. Tnis •ary wipe• removes or .Loosens any resiaue, such as dust, which was left from step 'a'. wipe the contacts witn at least six short strokes of t.-ie too.L. c. App.Ly more distilled water to the same tool ana wipe the tungsten tred) contacts. Immediately w1pe these contacts dry with t~e same dry C.J..eaning too.Las was previously used. a. Lmnediately bl.ow the contacts with filte:::ea compressed air to remove any loose aust. e. The washing and drying tools should then be wasned before re-use. E. If the contact resistance is still too high, burnish the contac~s with metailographic paper cut in strips 1/2 inch wide ana repeat steps 'a' to 'd' to remove tne dust formed. 4570-A, p. 10 UNION SWITCH Ii SIGN.AL If the contacts are burned or pitted and the operation per step 'f' does not successfully reduce the contact resistance, burnish the contacts in the direccion of slide with burnishing tool J397187. Follow with metallographic paper and repeat steps ·~· to 'd' to remove the dust formed. g. 4.2.2 Cleaning Relay contacts (Alternate) Recommended Cleaning Materials A relay contact cleaning kit, part number X4Sl646-0901, is available that consists of the following three items, or which may be ordered individually: Burnishing Tool, P.K. Neuses co. No. 3-316 Burnishing Tool, P.K. Neuses co. NO. N318 (Heavy Duty) Paper Strip, strips cut from 67 pound white Springhill Vellum Bristol Paper J397187 (pkg. of 5) J397187-001 (pkg. of 5) J793094 (pkg. of SO) Also recommended (commercially available) Emery Paper, Wet or Dry, 600 Grit, cut in strips Freon T~, ~iller Stephenson MS180 NOTS When using the paper strip, clean the silver/platinum contacts first, then the tungsten contacts last. oiscatd the paper strips when dirty. 4.2.2.l Contacts That Are severely Burned a. osing a 600 grit emery paper strip folded with the grit side out so that both contacts can be burnished simultaneously, stroke the contacts in the direction of contact wipe. b. Using the burnishing tool, stroke the contacts several times in the direction of contact wipe. c. Place the paper strip between the open contacts, then close the contacts and withdraw the paper strip. d. Repeat steps •c• several times if necessary. e. using the Freon TF spray, give the contacts a degreasing/wash. f. Place the paper strip between the open contacts, then close the contacts and withdraw the paper strip. g. Repeat steps •f• several times iE necessary. contac~s Wit~ Heavy Tacnish, Slightly Rough or Pitted a. Petform the procedure in paragraph 4.2.2.1, Steps •o• to •g•. 4570-A, p. 11 UNION SWITCH & SIGNAL 4.2.2.3 a. 4.3 contacts With surface Film or oxidation (Not Pitted) Perform the procedure in paragraph 4.2.2.1, Steps •fft and •g• CHECK-OUT PROCEDURE (PerEor~ance Test) Perform calibration in accordance with paragraph 4.6. 4.4 REPAIRS AND REPLACEMENT Since the contacts are the major wearing parts in this relay, in most cases the relay can be restored to proper operation by dressing and readjusting them. 4.4.1 Recommended Tools and Test Equipment Magnet Tester N245416 Magnet Charger N249003 Gram scale - 0-30 grams Gap Gauge - 0.001-0.055 in. Spacer - 0.124 in. 4.4.2 Disassembly Dismantle the relay only to the degree necessary to complete repairs. Refer to the parts list appendix for part infor~ation and location of parts. In general, to dismantle the plug-in relay, proceed with the following sequence: a. Remove relay cover seal. b. Carefully remove plastic cover. c. Remove the operating unit as required • d. Remove contact assembly as required. e. Remove contacts/contact springs as required. f. Disassemble the operating unit as required. 4.4.3 Reassembly Reassembly is accomplished generally in the reverse order of disassembly. The following paragraphs provide additional instructions to be followed during reassembly of this relay. 4570-A., p. 12 UNION SWITCH & SIGNAL 4. 4. 3 • .1. Con tact Sf)r 1.ng Support If the conta~t Sf)cing support has been removed, it shouid be check~a w1.th a straight eage that tne forward and rear hL~ge springs are accurately in line with each other as mounted on the con::.act block. With the spring support reassemoled, each contact spring should be mai ...fr I<. ,i,. VI ~ 0 I ;i:, - - · · · - · · ..·Cl ....................... ...,I I .. , •• t. , , •••••••••• , , • ' ·······-·· .o,,,, ••••• ~ Idc:==t I 11111 I -€® c z az ~ ~ n J.: R> 'O :r 1.,J Ill G) z )> r 83 UNION SWITCH & SIGNAL ?\~TS LIST FOR op~qAT!NG GN!T FOR ?C-250P q~lay ( see ':?' i q,1 c e .i.. 2 l qeference Operat.i.ng Unit Part I N"3941363 N384864 N3S4865 111435855 "1'"394863-001 111384865-002 A R c 1) F.: I ITEM NO. F Pa.RT "I'(). "lo • DF.:SCR !?'t'I ON OSF.:D 0111 i:tELA.Y REF. I 1 2 3 4 5 6 7 8 g I I 10 lO 11 12 12 12 12 12 l3 14 15 l 'i 17 13 19 20 21 ~298999 "t382789 M3S 2790 J4630SS JO 47710 J048172 M298990 "1289302 "1299005 N384852 N384853 "tlS7S75 N34'508~ N299044 N384787 N384787-00l lll3134797-002 J04770S "!001505 J047709 "tl97l82 "t29899l JO 51250 M382791 J'5 22153 J522149 Back Strap J:lear "1tg. sracket Front Mtg. 13racket Screws, U0-32 x: 1-1/4" 8: :{. Stl. T. ?l. washers, no Shakeproof '?h. Brz. N .P. Nut, H0-32 Hx. Stl. T. Pl. Pole Piece 80 lt Pin Coil Compl. coil Comi;,l. Pole Piece Contact Assembly contact Assembly SP.e Note ;.. " contact Assembly contact. Assembly contact Assembly washer, ~5 P'1. Brz. Shake Prf. Lock Ill. Pl. Nut. washer, JS Pri. Brz. Shake ?r:f. ~ock. "I' • 1? l. -1agnet !.tagnet clamp screws, 18-32 l( 2-1/2" Lg. Fi 11. "l'ylok Frame screws, H0-32 l( 3 /4 • Lg. Fi 11. IIIylok Screws, JS-32 x: 1/2 • Lg. Fi.ll, l\lvlok . ALL A.LL A.LL A.LL ALL l\.LL ALL ALL AT...L A,B C-F ALL A. 8, D c F.: F a.r...L 21,,LL 21,,ll l\LL 21,,LL ALL ALL ?-.Lt.. ALL NO't'E "A" - contact su~-A.ssembly detailed on Figure .i..3 and itemized on separ.~te tabulation. 4570-:\, p. A.-4 (Rev. 1/87) UNION SWITCH&: SIGNAL Figure A2. ~ PC-250P Operating Unit Details 4570-A, p. A-5 Cfj UNION SWITCH & SIGNAL PARTS LIST FOR CONTACT ASSE~BLY ( see Fig~ re AJ l ReEerence N345089 N289044 N384797 N384787-001 N384787-002 A !3 c D I E !TE:1 l 2 3 4 5 6 i 8 9 10 11 12 l3 14 15 16 17 18 19 20 21 NO. contact z..ss~mb ly Part No. PART NO. ~288987 M2S89S3 N2890l0 J05 l384 JO 47708 M288994 N288995 N289011 M001505 :'1107722 Ml02525 M221049 N299002 N288998 N28903S N224184 N224135 N224184 N224185 N28899S N2S9038 4570-A, p. A-6 used on 09erat~nq Unit With ReE. Lett.er A B & D c E F DESCRIPTION Contact Mount ing Block contact Spring Support Front Hinge screw, #6-40 x 7 -16" Lg. Fill. Hd. Brass washers, J6 Phos. Srz. Sh. Prf. screw Flexible connector Rear Ringe Nut GU ide SpC'ing Stop GU ide Armature Normal contact Post Normal contact ?ost Normal contact Spring Normal contact Spring Reverse contact Spring Reverse contact Spring Reverse contact post Reverse Contact Post USED ON RELAY REF. .l\LL ALL ALL ALL ALL ALL ALL ALL ALL A,9 ALL ALL .~LL see Table Figure A3 {Rev. 1/97 l UNION SWITCH & SIGNAL ffi ORNRLCCLJTAC7' .5PJc:;11J~ RE.VE: RSE