Sm-6215

Transcript

SEE ATTACHED ADDENDUM SERVICE MANUAL 83.. 6215 BROKEN JOINT AND OVERRUN DETECTOR BJORD-10 November, 1981 A-81-250-2405-1 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC. Swissvale, PA 15218 .-·:.~ ..,,.. -il>-'s /! ., ,.._ ....'1 .r !-. } .. , rfi6"'1!>·. '!. . .. w. ··-·). .i" ; :;, ;! '· ~.-~· ."$:---~::': \ )i,, j ·< ~. ~t r ; i .,5 , z: l .. l UNION SWITCH & SIGNAL TABLE OF CONTENTS {CONT.) Section 5.4 5.5 Locating Faulty Circuit Board. • . Page . . . . . . 5-4 5.4.1 Transmitter Troubleshooting . . . . 5.4.2 Receiver Troubleshooting . . ~ . . . 5-4 . . 5-6 Detailed Troubleshooting . . . . . . 5.5.1 . . . . 5-6 Transmitter Detailed Troubleshooting . . . . 5-6 5.5.1.1 18 kHz Oscillator Section. . . 5-8 5.5.1.2 460 Hz Modulator Section. . . 5-8 5.5.1.3 5.6 Modulator Amplifier and Power Driver Amplifier Section . . . . . 5-8 5.5.1.4 Power Amplifier Section. . 5-9 5.5.2 Receiver Detailed Troubleshooting. . . 5-10 Component Replacement Notes . . . . . 5-11 5.7 Calibration . . . . 5.7.1 Transmitter Pre-Calibration Instructions . . 5-12 5.7.2 Transmitter Adjustments . . 5.7.3 Receiver Adjustments . . . . . 5.7.4 Setting Transmitter Gain . . . . . . . . . . 5-15 5.7.5 System Checks. . . . . . 5.7.5.1 5.7.5.2 5.7.5.3 5.8 APPENDIX A . 5-12 . . 5-12 . 5-14 . . . . . . . 5-15 Receiver Sensitivity Test . . . . . 5-16 Shunting Tests . . . 5-16 Transmitter Output Characteristics Across Bond . . . . 5-16 5.7.5.4 Receiver Input Current Versus Relay Voltage Test . . . . . . . . 5-18 5.7.5.5 Receiver Bandwidth Test . . Post-Repair Inspection. . 5-18 . . . 5-21 PARTS LIST FOR BROKEN JOINT AND OVERRUN DETECTOR BJORD-10 . . . . . . . . . . . . . . . . A-1 A-1 BJORD Assembly . . . . . . . . . . A-2 Transmitter Printed Circuit Board . . A-3 Receiver Printed Circuit Board. • • • • • • • • • A-6 Component Board Assembly . • . . . . . . . A-8 A-4 A-2 . . . A-4 iii EB m UNION SWITCH & SIGNAL LIST OF ILLUSTRATIONS Figure Title Page 1-1 Broken Joint and Overrun Detector, BJORD-10. 1-2 BJORD-10 Location of Major Components. 2-1 Typical BJORD-10 Installation in Wayside Signaling System . . . . . . . . . . . . . . . . . . . . . . . . 1-2 • • • . . . . 1-4 3-1 Vital Functions of BJORD . . . • . . 3-2 Transmitter Printed Circuit and Component Boards, Circuit Diagram (Drawing D451318, Sheet 2401) • . . 2-4 • • 3-2 . 3-4 3-3 Receiver Printed Circuit Board, Circuit Diagram . • • . • 3-6 5-1 Short-Circuit Transmitter Current Waveform • • . . • . . 5-5 5-2 BJORD-10 Shop Bench Test Configuration . . • 5-7 5-3 Transmitter Output Spectrum Characteristics Across Bond • • . • • • • • . 5-17 5-4 Receiver Input Current Versus Relay Voltage Characteristics • • • . • • . . . • . . • . . . 5-19 5-5 Receiver Input Filter Response Characteristics . A-1 BJORD Assembly . • . . . . . . . . A-3 A-2 Transmitter Printed Circuit Board Assembly. . . . . . A-5 A-3 Receiver Printed Circuit Board Assembly . . A-4 Component Board Assembly. . . . . • . • • . . . . . 5-20 . • • A-7 . A-9 LIST OF TABLES Table Title Page 4-1 Cleaning Agents and Materials . . • • • • 4-2 4-2 BJORD Inspection Chart . . . . . . 4-3 4-3 Recommended Test Equipment and Component for Field Maintenance. . . . . 5-1 5-2 iv . . . . . Recommended Test Equipment Maintenance. . . . . . . . and . . . . . . . . . Components for Shop . . . . . . . . . . . . . TBD Polypropylene Capacitor Selection . . . . . . . 4-5 5-2 5-14 ... UNION SWITCH & SIGNAL TABLE OF CONTENTS Section I ~Page GENERAL INFORMATION . . . • • . 1-1 1.1 Purpose of Equipment . • . • • . • . 1-1 1.2 Scope of Operation . . 1-1 1.3 Physical Description . . • • . . • • l-1 1•4 System Components. . 1-3 1.5 II 1.4.1 Power Supply. . •. 1.4.2 1.4.3 Parallel Resonant Filter . . . . • Vital Relay . . . • • . 1-3 1-3 1-3 Specifications . . . . 1-5 1.5.1 BJORD-10 Unit . . 1-5 1.5.2 System Equipment. 1-5 INSTALLATION AND ADJUSTMENTS . . . . . . . . 2-1 2.1 2-1 2.2 III . ...... . Installation ••.....••.•.... 2.1.1 Wayside Mounting 2-1 2.1.2 Power Supply Interface. 2-1 2.1.3 Track Interface . . . . . . . . 2-1 2.1.4 Vital Relay Interface 2-2 2.1.5 Installation Checks. 2-2 Minimum Performance Tests . 2-3 2.2.1 Rail Joint Shunt Test. 2-3 2.2.2 Rail-to-Rail Shunt Test . . 2-3 .. . FUNCTIONAL DESCRIPTION. . . . . • . . . . . . 3-1 3.1 General. . . . . . 3-1 3.2 BJORD Circuit Description . . . . . ..... 3-1 3.2.1 . . . . 3-1 Transmitter. . . . ....•....... . • . 3.2.1.1 Carrier Oscillator . . 3-1 3.2.1.2 Modulation Frequency Generator . . 3-3 3. 2. 1. 3 Modulation Amplifier. . . . . 3-3 3.2.1.4 Power Amplifier. . . . 3-3 i m ffi UNION SWITCH & SIGNAL TABLE OF CONTENTS (CONT.) Section Page 3.2.2 IV Receiver . . . . . . . . • 3-5 3.2.2.1 • 3-7 Operation • • FIELD SERVICE MAINTENANCE AND TROUBLESHOOTING . • . 4-1 4. 1 General • . . 4-1 4.2 Preventive (Scheduled) Maintenance 4. 2. 1 Cleaning (Annually) 4.2.1.1 4.2.1.2 v •.•. . 4-1 Cleaning BJORD-10 Exterior Surface . . • • . • . • . . 4-2 Cleaning Heat-Sink Mounted Components . . •• . 4-2 4.2.2 Inspection (Annually) 4.2.3 Performance Tests ...•..•• . 4-3 . 4-3 4.3 Troubleshooting . • . 4-3 4.4 Corrective Maintenance. • 4-4 4.4.1 Recommended Test Equipment and Components for Field Maintenance. . • • • • . . • 4-4 4.4.2 BJORD-10 Checks . 4.4.3 Removal and Replacement of BJORD-10 . . . • 4-4 . . . . . . . • . . . 4-4 SHOP MAINTENANCE AND TROUBLESHOOTING • . 5. 1 General. 5.2 Recommended Test Equipment and Components for Shop Maintenance . . . . . . . • . . . . 5.3 . . . . 5.2.1 Fabrication of 10-Foot Shunt . . 5.2.2 Fabrication of 35-Foot Shunt. 5. 2. 3° Fabrication of 200-Foot Shunt. Disassembly. . • 5-1 . 5-1 . 5-1 . . 5-1 5-1 . . 5-2 . . 5-3 5. 3. 1 Removal of BJORD-10 From Case 5-3 5.3.2 Removal of Transmitter Printed Circuit Board . . . . . . . . . . . . . . . 5-3 5.3.3 5.3.4 ii 4-1 Removal of Receiver Printed Circuit Board . . . . . . . . • . . . . . . 5-4 Removal of Component Board. . 5-4 UNION SWITCH Ir SIGNAL ffi SAFE'l'Y SUMMARY Safety precautions that must be observed when performing certain tests are cross-referenced by test and paragraph number. The specific ( WARNING I is placed prior to the performance of a particular step in a test. TEST PARAGRAPH NO. When performing maintenance tasks, no additional safety precautions are required, other than coamon safety practices. v/vi ... UNION SWITCH & SIGNAL ffi SECTION I GENRAL INFORMATION 1.1 PURPOSE OF EQUIPMENT The Broken Joint and Overrun Detector (BJORD-10, refer to Figure 1-1} provides a means of detecting electrically defective insulated rail joints and also detects the passage of train wheels at interlocking boundries (bond locations). The BJORD-10 operation is particularly necessary to prevent cab signal spillover from an interlocking track circuit into an approach track, and is also used by the wayside signal system to determine if a train has overrun a stop signal. 1.2 SCOPE OF OPERATION The BJORD-10 is an audio-frequency device, consisting of a mitter and receiver, which is installed at double impedance bond (Z bond} track locations. Operating at a carrier frequency of 18 KHz, modulated at 460 Hz, the transmitter output is connected across an insulated joint of one rail. The receiver is connected across the opposite insulated joint at the same location. The transmitter sig- nal is coupled to the receiver via the autotransformer action of the z bond. The receiver input signal strength is sufficient for the receiver output signal to energize a vital output relay which interfaces with the wayside signaling system. Should the insulated joint(s) break down for some reason, or should a train pass over the insulated joints, signal energy from the transmitter is shunted away from the receiver input. When this occurs, the receiver output sig- nal becomes insufficient to maintain the vital output relay in the energized (picked} condition and the relay armature drops. 1.3 PHYSICAL DESCRIPTION (See Figure 1-2) The BJORD-10 components are housed in a metal case with remov- able top and front covers. Attached to the underside of the top cover are two brackets which support the transmitter and receiver printed circuit boards. The top side of the cover has an AAR 8- terminal block, fuse holder for a 3-ampere slo-blo fuse, and two feed-through grommets for wiring internal boards to the AAR terminals. The terminal block provides all connections for input 1-1 UNION SWIT!;H & SIGNAL Figure 1-1. 1-2 Broken Joint and Overrun Detector, BJORD-10 UNION SWITCH & SIGNAL ffi power (+12 vdc), transmitter output, receiver input and relay drive output. The front cover is perforated to permit air circulation to transmitter heat-sink mounted components which are mounted to the component board. Signals leads from the transmitter and receiver printed circuit boards are hard-wired to their respective terminals on the component board (transmitter only) and AAR terminal block. The case is provided two mounting brackets which permit shelf, wall or rack installation. 1.4 SYSTEM COMPONENTS In operation, the BJORD-10 requires several external system components which include a power supply, 18 KHz parallel resonant filters and a relay. 1.4.1 Power Supply An external +12 vdc power supply (part no. J725709-0073) is required for operation of the BJORD-10 transmitter circuit. This supply must be capable of delivering +12 vdc +/- 5% at 5 amperes to the BATTERY (+and-) terminals of the BJORD-10. 1.4.2 Parallel Resonant Filter One or two 18 KHz parallel resonant filters (part no. N451561- 0301) are required for series connection between low impedance sources and the rails to prevent loading down the 18 KHz BJORD-10 signal. 1.4.3 Vital Relay A single vital relay of the type PN-lSOBH (N322511-006), having a 400 ohm coil, is required to interface with the wayside signaling system. The receiver output is connected between relay terminals +T and -A. 1-3 m UNION SWITCH & SIGNAL TOP COVER CASE MOUNTING BRACKET PERFORATED COVER Figure 1-2. 1-4 TRANSMITTER PC BOARD BJORD-10, Location of Major Components UNION SWITCH & SIGNAL 1.5 m SPECIFICATIONS 1.5.1 BJORD-10 Unit = 9-1/2", H = 9", D = Dimensions: W 7-11/16" Mounting: Two brackets: shelf, wall or rack mtg. Weight: 5-1/2 lbs. Temperature range: -40°F to +158°F (-4o 0 c to +7o 0 c} Transmitter: Carrier Frequency 18 kHz ±50 Hz Modulation Frequency 460 Hz ±10 Hz Short Circuit Current Temperature Range 5.8 to 6.0 amperes P-P* -4ooc to +1ooc Power Requirements +12 vdc ±5%, 2.5 amperes Receiver: Frequency 18 kHz ±50 Hz Input Sensitivity 350 ma rms ±15 ma (input current when relay armature just drops away}. Bandwidth 480 Hz ±20 Hz Temperature Range -4o 0 c to +10°c Power Requirements None (passive circuit) 1.5.2 System Equipment Relay Filter PN-150BH (N322-511-006) N451561-0301, 18 KHz+/- 50 Hz parallel-tuned, 480 Hz bandwidth Power Supply +12 vdc ±5%, 5-amperes, regulated Impedance Bonds 1-ohm or 4-ohm, style AZ or AC propulsion Track Circuit Minimum ballast 1/2-ohm/1000 ft.; 2500 ft. maximum on one side, 6000 ft. maximum on other side of joints. *Refer to Shop Maintenance, Section V. 1-5/1-6 UNION SWITCH & SIGNAL 83 SECTION II INSTALLATION AND ADJUSTMENTS 2.1 INSTALLATION 2.1.1 Wayside Mounting The BJORD-10 must be installed within a 100 ft. cable run of the insulated joints it services. The unit should be installed inside a standard wayside housing and is typically shelf-mounted. Place the BJORD-10 so that the grill on the side of the unit is well ventilated, and the AAR terminals and fuse are easily accessed. 2.1.2 Power Supply Interface CAUTION NO REVERSE POLARITY PROTECTION IS INCORPORATED INTO THE BJORD-10. MAKE CERTAIN CORRECT POLARITY IS OBSERVED WHEN CONNECTING WIRING, OTHERWISE EQUIPMENT DAMAGE MAY RESULT WHEN OPERATING POWER IS APPLIED. The BJORD-10 requires a power source of +12 vdc +/- 5% at 5 amperes. ohm. The power supply lead resistance should not exceed 0.15 Therefore, if 14 gauge wire is used, 60 feet is the maximum recommended lead length, and if 16 gauge wire is used, 35 feet is the maximum recommended lead length. The BJORD-10 is protected by a 3- ampere, 3 AG, 250-volt slo-blo fuse. The power supply leads should be twisted and contain at least 3 twists/foot for 14-, 12-, 10- or 6-gauge wire. 2.1.3 Track Interface (See Figure 2-1) The BJORD-10 is designed to operate into track circuits (with a minimum ballast resistance of l/2-ohm/1000 feet) where the circuit on one side is no longer than 2500 feet. The track leads should be no smaller than 14 gauge and should not exceed 100 feet in length. The track leads should also be twisted, with 3 twists per foot for 14-, 12-, 9- or 6-gauge wire. Figure 2-1 illustrates a typical BJORD-10 installation in the wayside signaling system. 2-1 m UNION SWITCH & SIGNAL 2.1.4 Vital Relay Interface The leads between the BJORD-10 and the vital relay should also be twisted (3 twists/foot) and should not exceed 20 ohms in resistance. NOTE Once the BJORD-10 has been interconnected with the power supply, track circuits and vital relay, installation is complete. The BJORD-10 requires no external adjustments, but must be checked for normal operation. 2.1.5 Installation Checks With power applied to the BJORD-10, the vital relay armature should be in a picked position. following checks: If this is not the case, make the (Refer to section 4.4). 1. Power supply voltage and polarity 2. Relay polarity 3. System wiring 4. BJORD-10 and track fuses 5. Track circuit parameters (ballast and other leads) 6. Relay voltage (17 vdc minimum) If the vital relay voltage is below 5 vdc and the system components and wiring are correct, either the track components (insulated joints or impedance bonds) or BJORD-10 is defective. Direct replacement of the BJORD-10 with a known good unit will indicate where the fault lies. If the BJORD-10 is faulty, refer to sections IV and V, as applicable, for maintenance procedures. 2-2 UNION SWITCH & SIGNAL 2.2 m MINIMUM PERFORMANCE TESTS Following the installation checks, the BJORD-10 must undergo shunting tests to insure proper operation. These tests include rail joint shunting (broken down joint detection) and rail-to-rail shunting (train detection). 2.2.1 Rail Joint Shunt Test Perform a rail joint shunt test as follows: 1. Connect a 1.0~ohm resistor (Dale type RH-25, or equivalent) across insulated joint of one rail. 2. Vital relay armature should drop away. 3. Disconnect 1.0-ohm resistor across insulated joint and connect it across insulated joint of opposite rail. 4. Vital relay armature should drop away. If relay armature does not drop away, check system wiring and replace BJORD-10 with known good unit. 2.2.2 Rail-to-Rail Shunt Test Perform a rail-to-rail shunt test as follows: 1. Connect a shorting jumper from rail-to-rail on one side of insulated rail joints. 2. Relay armature should remain picked up. 3. Remove shorting jumper and connect jumper from rail-to-rail on other side of insulated rail joints. 4. Relay armature should remain picked up. If vital relay armature drops, check for a low impedance loading the BJORD-10 signal. The parallel resonant filter (N451561-0301) is required to isolate the low impedance source from the BJORD-10 signal. Repeat steps 1 through 4; if relay armature drops, replace the BJORD-10 with a known good unit. 2. 2. 3 Rail-to-Rail Shunt Test (.Both Rails) Repeat step 1 of the previous section and connect a second rail- to-rail on the other side of the insulated joints. The vital relay armature should drop. 2-3 ~ N I c z 0 .i:= z ~ ~::c INSULATED JOINT Q:11 CII C) z):,, BOND ,~ NOTE 1 A R 120 VAC 100 HZ 120 VAC 60/100 HZ Tl R A N c. s P. F 0 R M E R . r-------' I I I BOND INSULATED JOINT 3 5 4 REC. TRANS. POWER SUPPLY ----- __________...... r 6 7 BJORD-10 SEE NOTE 3 2 NOTES: 1. "ALTERNATE 18KHZ FILTER LOCATION 2. 8 INDICATES TWISTED PAIR 3. ONLY LOW IMPEDANCE CONNECTIONS TO THE RAILS REQUIRE AN 18KHZ FIL TEA IN SERIES. NOT ALL JOINT LOCATIONS WILL REQUIRE TWO FILTERS. Figure 2-1. +TI I I ·A I _,,. Typical BJORD-10 Installation in Wayside Signaling System UNION SWITCH & SIGNAL ffi SECTION III FUNCTIONAL DESCRIPTION 3.1 INTRODUCTION The BJORD-10 is intended to simplify the equipment require- ments for monitoring of defective insulated joints.and train passage at interlocking boundries. It was developed primarily for operation on electrified railroads and performs two independent functions: detection of electrically faulty insulated joint material and detection of trains passing over insulated joints. The BJORD-10 uses separate transmitter and receiver circuits (operating with a modulated carrier frequency of 18 KHz) and uses a vital output relay for interfacing with the wayside signaling system. 3.2 Figure 3-1 illustrates the principal BJORD-10 functions. BJORD-10 CIRCUIT DESCRIPTION 3.2.1 Transmitter (See Figure 3-2) The transmitter generates an 18 Khz carrier frequency, modulated at 460 Hz, and operates into a 5-ohm output impedance capable od delivering two amperes into a short circuit. The transmitter consists of carrier oscillator Ql, modulation frequency generator ICl, modulation amplifier Q2/Q3 and power amplifier Q4 through Q7. 3.2.1.1 Carrier Oscillator The carrier oscillator circuit is a modified Colpitts, with capacitors C2 and C4 forming the tuning and divider functions for Ql. The secondary winding return at the junction of R7 and R8 is modulated with respect to ground by the frequency output from modulator ICl. 3-1 ffi UNION SWITCH & SIGNAL Rj o-t o"'7' ± T t-0 (Al BROKEN JOINT DETECTIONS: THE BJORD·10 SENSES WHEN Rj APPROACHES A SUFFICIENTLY LOW VALUE TO CAUSE A POTENTIAL SPILLOVER OF CAB SIGNAL. 0-i 8:)"B" I l-0 R ''A'' l-0 (Bl TRAIN DETECTIONS: THE BJORD·10 SENSES WHEN TRAIN"B" PASSES OVER THE INSULATED JOINTS AT EACH INTERLOCKING BOUNDARY Figure 3-1. 3-2 Vital Functions of BJORD-10 UNION SWITCH & SIGNAL 3.2.1.2 ffi Modulation Frequency Generator The modulation frequency generator consists of operational amplifier ICl connected in a familiar multivibrator configuration. Decoupling network R24/C8 prevents supply voltage variations from affecting multivibrator operation, while the combination of R9/C5, together with .a percentage of positive feedback via divider RlO, Rll and R12, determines the oscillation frequency of 460 Hz. About 4 volts of the output signal swing at the junction of R7/R8 drives the secondary winding return of modulation transformer Tl to provide turnon bias for modulation amplifi~r Q2/Q3. 3.2.1.3 Modulation Amplifier In the absence of the positive-going 4-volt, 460 Hz modulation signal, the input to modulation amplifier Q2 consists solely of the 18 kHz carrier signal (less than 1.0 volt peak-to-peak) from the secondary of transformer T1. Q2/Q3. Consequently, no output occurs from However, on the next half cycle of modulation, these tran- sistors are biased "on", giving a voltage gain at the collector of Q3 determined by the ratio of the resonant impedance of T2, C6 plus R15 plus R16 divided by R15 plus R16 (the latter serving as a gain adjustment). This resonant impedance is determined by "Q", since loading by the following stage has been made negligible. Q is in turn con- trolled by R17, so it can be seen that no failure can raise the gain of this stage. The output signal is coupled to the secondary winding of transformer T2 which provides the required isolation between the modulation amplifier circuit and the power amplifier stages. 3.2.1.4 Power Amplifier The power amplifier is of the push-pull type and consists of a pair of drivers Q5/Q6, which drive respective power output amplifiers Q4/Q7 (mounted on heat sink). Each driver-amplifier combination is arranged in a feedback connection such that gain is determined by the 3-3 w EE += c I z z 0 ! ~:r R> C/1 G) z l> r B•l2VOC R.6 CIA 2400 ~ R4 IK &f1c2 , RI TBO ft..r T·04 -4:-a&~, Rl IOK R2 4lK RII IOK Rl4 ,470• I Rll R'Zla 10" RIQ IK I o5 YI ..... ~ ".zv • Yl2ZA12 Cl ,01 I. LVA4"Z IOK L- IOOkr DI r--11--, ~--------+-=---in·~1 .on , I Rl3 R24 210" 24K 119 tl.ZK 06 l llt14 ~P2 RIS r o• C3 ,I RS IK RII IK RI& TBD Rl2 IOK 04 03 11<5368 IN5361 Rl9 IK -:-·GHO Figure 3-2. y Transmitter Printed Circuit and Component Boards, Circuit Diagram (D 451318, Sheet 2401) 5i. \ 25W AZIA UNION SWITCH & SIGNAL ffi impedance of a primary winding of T3 relative to emitter resistor R21 or R22. The collectors of Q4 and Q7 each serve as a current source and drive T3 as a parallel-resonant circuit whose impedance is determined by Q. By using transformer coupling to the rails, an isolated impedance match is provided at the carrier frequency, whereby the power amplifier circuit is presented with a high output impedance, while the rails see a low input impedance, since the secondary winding of T3, in conjunction with C9 and C9A combination appears as a series-resonant circuit. The heat sink power resistor establishes the output impedance. At frequencies lower than 18 Khz, the impedance of the series-resonant circuit increases sharply, thereby preventing the shunting of these signals. This arrangement allows one inductive output device to serve as both an impedance-matching transformer and a series-resonant circuit for coupling to the rails. If output tuning capacitor C9 shorts, which would short the rail joint for low frequencies, the output signal is reduced by 1/Q, (or 1/120} and the receiver output would drop, causing the vital relay to drop. Zener diodes D3 and D4 provide surge current protection for respective power amplifiers Q4 and Q7; varistor Vl also provides surge protection. 3.2.2 Receiver (See Figure 3-3) The receiver is a passive device, since it requires no external voltage for operation; it operates solely from the modula- ted 18 KHz input signal and consists of a series-resonant input circuit, full wave demodulator and a series pass transi3tor, and a parallel-resonant output circuit. This configuration results in a receiver which is simple, relatively immune to noise and which does not require excessive transmitter power. 3-5 EE c 2 0 w I C\ 2 i ~:c R» en a2 )> r ~1B r - -f ~-, I I I--,,-, ..J ~1A I I 3 I I C1 .082MFO. I 1 01 IN4936 01 2N3055 A T2 C Q .. 3191 ""::E C2 5MFO INPUT R1 2.2K 1/2W 4 02 1 + J---0 } J..--o T 2 I • • 03 .J 920 A& B. 0 IN4936 Figure 3-3. Receiver Printed Circuit Board, Circuit Diagram OUTPUT :~150 BH RELAY UNION SWITCH & SIGNAL 3.2.2.1 m Operation The receiver input consists of a series-resonant circuit provided by capacitor C1 and the primary winding of T1; varistor V1 provides current surge protection. The approximate Q of this input circuit is 20 which is achieved by the load characteristics of the following demodulator circuit and the vital output relay. The modulated carrier frequency of 18 kHz developed across the secondary winding of T1 is demodulated by full-wave rectifier D1/D2 and switching transistor Q1, thereby developing the highest possible percentage of input signal across the parallel-resonant output circuit consisting of capacitor C2 and the primary winding of T2. This results in transfer, by the secondary winding of T2, of maximum possible demodulated signal strength, which is converted to approximately +17 vdc for vital relay operation. 3-7/3-8 UNION SWITCH & SIGNAL ffi SECTION IV FIELD SERVICE MAINTENANCE AND TROUBLESHOOTING 4.1 GENERAL Field service maintenance and troubleshooting for the BJORD-10 is accomplished at two levels; namely, preventive (scheduled) maintenance and corrective maintenance. Both of these maintenance concepts are important, especially the former, since it decreases the possibility of equipment and system down-time. 4.2 PREVENTIVE (SCHEDULED) MAINTENANCE Preventive maintenance is a scheduled process whereby the BJORD- 10 is cleaned, inspected and tested on a periodic basis to insure that all functions are operational; to detect future possible causes of equipment malfunction; and to preclude the possibility of a complete breakdown with resultant down-time and loss of operation of the wayside signaling system. The following subparagraphs describe cleaning, inspection and minimum performance test procedures for the BJORD-10. 4.2.1 Cleaning (Annually) Cleaning of the BJORD-10 assembly should be accomplished at least once a year. The following subparagraphs outline cleaning procedures for the BJORD-10. Table 4-1 lists the cleaning agents and materials required, and their use. NOTE The BJORD-10 power supply (J725709-0073), normally shelf-mounted in close proximity to the BJORD-10, should also be cleaned at the same time as the BJORD-10. 4-1 EE UNION SWITCH & SIGNAL 4.2.1.1 1. Cleaning BJORD-10 Exterior Surfaces Dampen a lint-free cloth with a household cleaner and wipe exterior surfaces of unit free of dust and dirt. 2. Wipe surfaces clean with a lint-free cloth. 3. Attempt to blow out dust and dirt from inaccessible areas around terminal block, fuse-holder and BJORD-10 mounting surface. 4. 4.2.1.2 1. Wipe up loosened dust and dirt particles. Cleaning Heat-Sink Mounted Components Remove four screws and lock washers securing perforated cover to case and remove cover to expose heat-sink components mounted on component (micarta) board beneath. 2. Using a soft bristle brush, if available, remove dust and foreign matter accumulated on and around two power transistors Q4 and Q7 and power resistor R23. 3. Using a lint-free cloth slightly dampened with household cleaner, wipe inside surfaces of perforated cover. 4. Wipe surfaces with a clean lint-free cloth. 5. Install perforated cover over heat-sink components and secure in place with four screws and lock washers. Table 4-1. ITEM Cleaning Agents and Materials MANUFACTURER USE Household Cleaner Commercial Cleaning exterior surfaces Lint-Free Cloths Commercial Cleaning and drying exterior surfaces Soft Bristle Brush Commercial 4-2 ' Removing dust·and foreign matter from terminal block, covers and heat-sink mounted components. UNION SWITCH & SIGNAL 4.2.2 ffi Inspection (Annually) At least once a year, the BJORD-10 should be subjected to a visual inspection (preferably at the time of cleaning). Table 4-2 presents an inspection chart for the BJORD-10 and lists the items to be inspected and what to inspect for. Table 4-2. BJORD-10 Inspection Chart INSPECT FOR ITEM TG BE INSPECTED Exterior Surfaces Cleanliness, scratches, nicks, corrosion, secure mounting, loose hardware. Terminal Blo.ck Leads for cuts, nicks; terminal block for sequre binding nuts; terminal block for secure mounting, cracks. Fuse-Holder Cracks, loose mounting. Check fuse for integrity and proper value (3-ampere, , 3AG, 250V Littlefuse Co. #313003). 4.2.3 Performance Tests Performance tests for the BJORD-10 should be accomplished on a periodic 6-month basis to insure that all functions meet maximum performance criteria. These performance tests are the same as outlined in Section 2.2 following installation. 4.3 TROUBLESHOOTING Troubleshooting at the field level consists primarily of isolat- ing wayside signaling system faults to the BJORD-10. When this has been determined, the faulty BJORD-10 is replaced and is then returned to the shop for repair and calibration. Field troubleshooting is based upon the minimum performance tests in section 2.2, which are performed following installation. In general, if any one of these tests are unsuccessful: 1. 2. Rev. 3/83 Check fuse on BJORD-10. Check for +12 ±5% vdc between BJORD + and - BATTERY terminals. 4-3 ffi UNION SWITCH & SIGNAL 3. If not present, disconnect power supply leads from BJORD-10 AAR terminals and connect 2.5-ohm, 75-watt resistor across power supply terminals and check. that voltage is 12 ±5% at 4. 8 amperes. 4.4 4. Check +12 vdc power supply fuse. 5. Check system wiring. CORRECTIVE MAINTENANCE Corrective maintenance, within the capabilities of field _servic~ personnel, is limited to removal and replacement of fuses, voltage checks, system wiring checks and removal and replacement of the BJORD-10 itself. 4.4.1 Recommended Test Equipment and Components for Field Maintenance Recommended test equipment and components .at the field service level are listed in Table 4-3. Equivalent test equipment and compon- ents may be substituted. 4.4.2 BJORD-10 Checks BJORD-10 checks at the field service level consist of the instal- lation checks outlined in Section 2.1.5 and the minimum performance checks outlined in section 2.2. 4.4.3 Removal and Replacement of BJORD-10 The BJORD-10 is normally shelf-mounted within the wayside house and is removed and replaced as follows: 1. Disconnect and tag leads to BJORD-10 AAR terminal block. 2. Remove four screws and lock washers securing BJORD-10 to shelf and remove BJORD-10. 3. 4-4 Install replacement BJORD-10 unit using reverse procedure. UNION SWITCH & SIGNAL Table 4-3. Recommended Test Equipment and Components for Field Maintenance QTY NOMENCLATURE MFR DESIGNATION 1 Digital Multimeter Fluke 8010A 1 1.0 - Ohm Resistor Dale type RH-25 2 Shorting Jumper 10 gauge, 6-feet 1 2.5 - Ohm Resistor, 75 W Any 4-5/4-6 ffi UNION SWITCH & SIGNAL ffi SECTION V SHOP MAINTENANCE AND TROUBLESHOOTING 5.1 GENERAL This section presents shop maintenance and troubleshooting. procedures for a BJORD-10 unit which has been found defective during field service maintenance and troubleshooting. Included are a listing of recommended test equipment and components; disassembly procedures; board level and component level troubleshooting procedures; repair procedures; adjustment and calibration procedures, and final preshipment inspection procedures. 5.2 RECOMMENDED TEST EQUIPMENT AND COMPONENTS FOR SHOP MAINTENANCE The recommended test equipment and components required for shop maintenance and troubleshooting are listed in table 5-1; sections 5.2.1 through 5.2.3 outline fabrication requirements for the 10', 35' and 200' shunts. The purpose of these shunts is to simulate the im- pedance of the track with shunting train axles at various distances from the insulated rail joints, with a track ballast of 1/2 - ohm/1000 feet. The 10' and 35' shunts are simply inductors; the 200' shunt is an inductor/resistor combination. 5.2.1 Fabrication of 10-Foot Shunt The 10' shunt is wound with 14-gauge wire on micarta tubing with a 1-7/8" outside diameter as follows: e>-u...A...v--0 L 5.2.2 = L 5. 7 µ Hy consisting of 9. 5 turns. Fabrication of 35-Foot Shunt Two 35' shunts are required; each is wound with 14-guage wire on micarta tubing with a 1-7/8" outside diameter as follows: ~ L L = 16. 5 µ Hy consisting of 20 turns. 5-1 ffi UNION SWITCH & SIGN.AL 5.2.3 Fabrication of 200-Foot Shunt The 200' shunt is wound with 14-gauge wire on micarta tubing with a 1-7/8" outside diameter as follows: L ~ L Table 5-1. R R = = 33. 9 µ Hy consisting of 34. 5 turns. 4 . 0 ohms . Recommended Test Equipment and Components for Shop Maintenance QTY 5-2 NOMENCLATURE MFR DESIGNATION 1 Oscilloscope Tektronix 314 1 Current Probe Tektronix P6021 1 Scope Probe (X10) Tektronix P6006 1 Digital Multimeter Fluke 8010A 1 Frequency Counter HP5326A 1 VTVM (Battery Operated) HP 403A 1 Power Supply (12 vdc, SA) HP 6267B 1 Decade Resistor GR 1432-K 1 Decade Resistor GR 1433-L 1 Decade Capacitor Cornell-Dubilier CDA-5 1 Decade Capacitor Cornell-Dubilier CBD-3 2 AC Propulsion Bonds N451003-0501 or N451003-0801 1 18 kHz Filter 1 Relay (400-ohm coil) N451561-0301 PN-150-BH (N 322511-006) 1 Shunt Simulator (10') Refer to section 5.2.1 2 Shunt Simulator (35') Refer to section 5.2.2 1 Shunt Simulator (200') Refer to section 5.2.3 UNION SWITCH & SIGNAL 5.3 5.3.1 DISASSEMBLY (See Figure A-1.) Removal of BJORD-10 From Case 1. Remove four screws and lock washers securing perforated cover over heat-sink mounted components and remove cover. 2. Remove four screws and lock washers (two on each side) securing top cover to case. 3. Carefully lift top cover and component board up until transmitter and receiver printed circuit boards clear case. 4. 5.3.2 Carefully place assembly on bench work surface. Removal of Transmitter Printed Circuit Board 1. Remove BJORD-10 assembly from case as outlined in section 5.3.1. CAUTION WHEN UNSOLDERING LEADS AND/OR COMPONENTS FROM PRINTED CIRCUIT BOARDS, USE A HEAT-SINK, SUCH AS NEEDLE-NOSE PLIERS OR ALLIGATOR CLIPS, TO PREVENT HEAT FROM DAMAGING COMPONENTS. 2. Using a low wattage (35 watts, maximum) soldering iron with pencil tip, unsolder and tag leads from terminals on transmitter board. 3. Remove lacing cord, in three places, securing leads to printed circuit board. 4. Remove two cable clamps securing leads to printed circuit board. 5. Remove six screws and lock washers securing printed circuit board to support brackets and remove transmitter printed circuit board from BJORD-10 assembly. 5-3 ffi UNION SWITCH & SIGNAL 5.3.3 Removal of Receiver Printed Circuit Board 1. Remove BJORD-10 from case as outlined in section 5.3.1. 2. Using a low-wattage (35 watts maximum) soldering iron with pencil tip, unsolder and tag leads to two input and two output terminals. 3. Remove six screws and lock washers securing printed circuit board to support brackets and remove receiver printed circuit board from BJORD-10 assembly. 5.3.4 Removal of Component Board 1. Remove BJORD-10 from case as outlined in section 5.3.1. 2. Using a low-wattage (35 watts maximµm) soldering iron with pencil tip, unsolder and tag leads to six terminals and from two terminals on power resistor. 3. Slide leads under clamp and separate component board from BJORD-10 assembly. 5.4 LOCATING FAULTY CIRCUIT BOARD The procedures in sections 5.4.1 and 5.4.2 are used to determine whether the transmitter or receiver printed circuit board is faulty. The transmitter board must be tested first because a good transmitter board is required for the receiver board test. Only the transmitter board which accompanies the receiver board can be used in the latter test. 5.4.1 Transmitter Troubleshooting 1. Remove BJORD-10 assembly from case as outlined in section 5.3.1. 2. Apply 12 vdc (5 amperes) power to BJORD-10 input, terminals 1 (-) and 2 (+) of terminal block. Short transmitter output, terminals 3 and 5, of terminal block. 3. Using current probe (10 ma/mv range) and oscilloscope, measure peak-to-peak short-circuit current. range is 5.6 to 6.0 amperes peak-to-peak. 5-4 Short ~16. Acceptable (See Figure 5-1.) ffi UNION SWITCH & SIGNAL 5.4.2 Receiver Troubleshooting 1. Remove BJORD-10 assembly from case as outlined in section 5.3.1. 2. Connect BJORD-10 assembly in shop test configuration as shown in Figure 5-2. 3. Apply 12 vdc power to test setup and note if relay armature is in picked position (LED indicator illuminated). 4. If step 3 fails, refer to detailed receiver troubleshooting in section 5.5.2. 5. Monitor relay coil voltage with digital multimeter. Apply joint resistor (1.15 ohm) as shown in Figure 5-2. Relay voltage should be approximately 3.75 vdc, +/- .05 6. vdc. If relay voltage is not within specified range, refer to detailed receiver troubleshooting procedures in section 5.5.2. Adjust decade box across Rl6 terminals slowly down to 0.0 ohms; this permits a gradual increase in power output as opposed to an abrupt change. Note: power sup- ply current is no more than 4.5 amperes. 5.5 5.5.1 DETAILED TROUBLESHOOTING Transmitter Detailed Troubleshooting (See Figure 3-3) The transmitter circuit is divided into four sections for trouble isolation purposes. These sections include the 18 kHz oscillator, 460 Hz modulator, modulator-amplifier and power driver amplifier, and power amplifier. The components and measured voltages associated with each of these circuit sections are described in sections 5.5.1.1 through 5.5.1.4. NOTE All voltages are measured with respect to ground except where otherwise noted. The transmitter output and R16 are both short-circuited. supply voltage is set for 12 vdc ±0.1 vdc. 5-6 Power UNION SWITCH & SIGNAL ~ ~ _...A rt11 .......4 ~ ~ ~ ffi .5 MSEC/DIV. tOOMV/DIV. P6021 CURRENT PROBE 10 MA/MV CURRENT INDICATION• 6 AMP. PEAK TO PEAK Figure 5-1. Short-Circuit Transmitter Current Waveform If this waveform and level cannot be duplicated, the transmitter calibration procedure must be followed. Once the transmitter has been calibrated, the receiver must also be calibrated, whether the receiver was in need of repair or not. gether as a matched pair. The receiver and transmitter work to- Any changes in transmitter frequency out- put impedance or waveform will affect receiver performance, thus, requiring re-calibration. 4. Refer to calibration procedure. Measure carrier frequency at TP2 (Q1 emitter) using frequency counter; frequency should be 18.0 kHz ±50 Hz. 5. Measure modulation frequency at TP1 using frequency counter; frequency should be 460 Hz ±10 Hz. If short circuit current is borderline, a slight adjustment of T1 and/or tuning slugs may compensate for the discrepancy. Adjusting T1 tuning slug changes the 18 kHz oscillator frequency and a frequency measurement at TP1 must be made to insure a ±50 Hz tolerance. 5-5 POWER SUPPLY 12VDC6A SEE FILTER DETAILS BELOW BJORD SHORT JUMPER + 1 2 18 KHZ F I L SHUNT 200' 35' CT BOND SHUNT 10' BOND . 7 8 ... 35' T RELAY I+ E R SIMULATED JOINT SHORT JUMPER rC1A _i_ '1" L_ FILTER DETAILS (PART NO. N451561-0301) T1 .082 µfd I I I +T I RELAY PN 150 BH N451428·0101 I NOTE: L1 I I SHORT JUMPER 2P c, I ·A t:BOND GERD·Y· B 1P 1. FILTER: L , POT CORE 4229 PA160 3C8 1 74 TURNS 75/40 LITZ WIRE T , W-400 TRANSFORMER 1 10=1 TURNS RATIO c 1A' SELECT FOR 18 KHZ +50HZ TUNING 2. ~ RELAY SPEC. ,:- - - --"l 1~/1 IL Y il#LEDI ______ :J CONTACT POSITION INDICATOR INDICATES TWISTED PAIR c z 5 z I ~ :i::: 11!1 Cl) 15 z Vl I -..J ... )> Figure 5-2. BJORD-10 Shop Bench Test Configuration EE ffi UNION SWITCH & SIGNAL 5.5.1.1 18 kHz Oscillator Section The components associated with the 18 kHz oscillator section are: 01, R1, R2, R3, R4, RS, R6, C1, C2, C3, C4, T1, Q1. Circuit Monitoring Points Indications Across D1 TP2 (Ql, emitter) Q1 base Q1 collector 'Across T1 secondary 5.5.1.2 6.2 vdc ±5% .50 vdc +/- 10% 1.00 vdc +/- 10% 5.75 vdc +/- 5% 1.22 V peak-to-peak 18 Khz sinewave measured using P6006 X10 probe and scope 460 Hz Modulator Section The components associated with the 460 Hz modulator section are: R7, R8, R9, R10, R11, R12, R24, CS, Circuit Monitoring Points Junction of R24 and Pin 6 of IC1 5.5.1.3 ca ca, IC1. Indications 11.64 vdc ±5% 10.0 V peak-to-peak squarewave 460 Hz ±10 Hz measured using . P6006 X10 probe and scope Modulator Amplifier and Power Driver Amplifier Section The components associated with the modulation amplifier and driver amplifier sections are: R13, R14, R15, R16, R17, R18, R19, R20, R25, C6, C7, Q2, Q3, QS, Q6, T2, 02, D5, D6. 5-8 Circuit Monitoring Points Indications Q2 Q2 Q2 Q3 Q3 Q3 2.29 vdc ±5% 1.87 vdc ±5% 11.70 vdc ±5% 12.0 vdc ±5% 11.77 vdc ±5% 2.30 vdc ±5% emitter base collector emitter base collector UNION SWITCH & SIGNAL Circuit Monitoring Points m Indications Each side of T2 secondary: .5 msec/div. 100 mv/div. P6006 X10 probe Voltage, T2 secondary (either side) to ground Junction 02 and R18 11.4 vdc ±5% Q5 Q5 Q5 Q6 Q6 Q6 11.60 11.36 .57 11.60 11.36 .57 5.5.1.4 emitter base collector emitter base collector vdc vdc vdc vdc vdc vdc ±5% ±5% ±3% ±5% ±5% ±3% Power Amplifier Section The components associated with the power amplifier section are: R21, R22, R23, C9, 03, 04, Q4, Q7, T3, V1. Circuit Monitoring Points Indications Q4 Q4 Q7 Q7 • 57 11. 60 . 57 11. 60 base collector base collector Open circuit output voltage vdc vdc vdc vdc ±3% ±5% ±3% ±5% 2.7 vrms ±5% measured with 403A VTVM After the transmitter is repaired, check the short-circuit output current using the P6021 current probe and scope. The waveform should resemble that of Figure 5-1 and should be 5.8 to 6.0 amperes peak-to-peak. 5-9 ffi UNION SWITCH & SIGNAL 5.5.2 Receiver Detailed Troubleshooting Component level testing of the receiver board also requires the accompanying transmitter board. be in good working order. to the receiver tests. The transmitter must be verified to The test set up shown in Figure 5-2 applies The components and measured voltages of each of the curcuit sections are as follows: NOTE R16 in the transmitter is to remain shortcircuited and the output of the transmitter is connected to the test configuration as shown in Figure 5-2. The schematic diagram is shown in Figure 3-4. Circuit Monitoring Points Indications Input to receiver 2.7 to 3.Q vrms measured with HP403A VTVM. 16.0.to 78.0 vrms measured with HP403A VTVM. 10.25 to 11.0 vdc (this point, as seen on oscillo~cope, is shown below) Across full secondary of T1 Emitter of Q1 to centertap of T1 .5 msec/div. 10V/div. r • '/ ' I ' \.J I ..... l J ~ " '- Voltage Waveform at Q1 Emitter to Centertap of T1 Secondary 5-10 I I UNION SWITCH & SIGNAL ffi Circuit Monitoring Points Indications Emitter to base Q1 .5 vdc ±.02 vdc {meter ground lead on base) 58.0 to 60 V peak-to-peak 460 Hz ±10 Hz sinewave 18.5 vdc ±.5 vdc Across C2 DC side of 03 NOTE Once the necessary receiver repairs have been made, the receiver sensitivity must be measured to verify proper operation. Refer to the receiver functiona~ block troubleshooting in section 5.4.2 for this procedure. If the receiver fails the input sensitivity test, refer to the calibration procedure in section 5.7. 5.6 COMPONENT REPLACEMENT NOTES Repair of the BJORD-10 consists primarily of replacing PC board components which have been found to be defective through the troubleshooting process. In general, whenever components are to be replaced on a printed circuit board: 1. Always use a heat-sink, such as needle-nose pliers or alligator clips, on the leads of the component to be removed/ replaced, to prevent component damage. 2. Use a low wattage soldering iron (35 watts maximum) with pencil tip for unsoldering component leads. 3. Scrape away spraycoat from around component and leads prior to unsoldering component. 4. After component replacement, apply spray or brush coat of CONAP CE-1163 Polyurethane (or equivalent) to repaired area. 5-11 ffi UNION SWITCH & SIGNAL 5.7 5.7.1 CALIBRATION Transmitter Pre-Calibration Instructions (See Figure 3-3.) Initial adjustments to the transmitter can be made before the BJORD-10 is wired into the test setup shown in Figure 5-2. Complete the following steps before applying power to the BJORD-10. 1. Use clip leads to temporarily wire decade box across terminals of R9A and set box to 2.8K-ohms. 2. Use clip leads to temporarily wire decade box in place 3. of Rl6 and set to 100 ohms. Use coaxial cable to temporarily connect frequency counter from TP2 (emitter of Q1) to ground. 4. Use short clip-lead to temporarily short output of transmitter (terminate 3 and 4). 5. Use clip-lead to temporarily short out CS in modulator circuit. 6. Remove fuse and use short jumper to bypass fuseholder so that power can be applied to unit for remainder of test without danger of blowing fuse. CAUTION PERIODICALLY REMOVE THE CS SHORTING JUMPER TO MINIMIZE THE POWER DISSIPATION DEMAND ON THE COMPONENT BOARD OUTPUT TRANSISTORS, OTHERWISE THE TRANSISTORS MAY BE DAMAGED. 5.7.2 Transmitter Adjustments (See Figure 3-3.) 1. Apply power to BJORD-10. than 1.0 ampere. 2. Note that power current is less If not, check circuitry for improper wiring. Adjust tuning slug of T1 until frequency counter indicates 18.00 kHz ±50 Hz. If adjustment is beyond range of T1 slug, pad capacitor C2 with value chosen from list of TBD capacitors in Table 5-2. range. 5-12 T1 slug should be near center of its UNION SWITCH & SIGNAL x 3. m Adjust decade box (across Rl6 terminals) slowly down to 0.0 ohms; this permits a gradual increase in power output as opposed to an abrupt change. Note: power supply current is no more than 4.5 amperes. 4. Check frequency counter and verify 18.00 kHz ±50 Hz; seal T1 tuning slug. 5. Remove shorting jumper from CS and connect frequency counter to TP1 (junction of R7, R9 and R10). Adjust decade box across R9 until counter indicates 460 Hz ±10 Hz. Measure value of decade resistor (R9A) and duplicate that value with standard 1/2-watt ±5% carbon resistor. Replace decade box with carbon resistor. 6. Reconnect jumper across CS. 7. Connect decade capacitor (CDA-5) across C9. 8. Clamp current probe around shorting jumper at transmitter output. Set multiplier switch on probe to 10ma/mv and connect probe to oscilloscope. sweep rate to 0.5 msec/DIV. Set scope to 100mv/DIV and Steady carrier current at 18 kHz, should be observed as modulator is shut down, because of short across CS. 9. 10. Connect current probe to battery-operated VTVM (HP 403A}. Adjust capacitance decade box across C9 until 18 kHz current is peaked. 11. Adjust tuning slug of T2 for an even higher current peak, and then re-adjust decade box for peak, if necessary. optimum peak is achieved, seal T2 tuning slug. should be no less than 0.18 vrms. Once VTVM reading Note values of capaci- tance decade box and duplicate that value with a combination of capacitors selected from list of TBD polypropylene capacitors· in Table 5-2. Preferred method of duplicating capacitance is by measurement rather than reading nominal values of decade box and capacitors. Check for duplication of peak or better. 12. Turn off power supply. 5-13 ffi UNION SWITCH & SIGNAL Table 5-2. TBD Polypropylene Capacitor Selection COMMODITY NO. DESCRIPTION .001 polypropylene 400 VDC ±5% TWR #USS-3 II .001 II .0022 II .003 II .0039 II .005 .01 polypropylene ±5% TWR Type X363 UN II .015 .018 II . 022 II .033 II .039 II .047 .068 TWR Type X363 UN II .082 II •1 .12 " . 15 " .22 " It .33 J709145-0454 J709145-0455 J709145-0456 J709145-0457 J709145-0458 J709145-0459 J709145-0438 J709145-0439 J709145-0440 J709145-0441 J709145-0442 J709145-0443 J709145-0445 J709145-0446 J709145-0447 J709145-0448 J709145-0449 J709145-0450 J709145-0451 J709145-0452 5.7.3 . Receiver Adjustments (See Figure 3-4.) 1. Connect BJORD-10 into test setup as shown in Figure 5-2 less shunts and RJ. 2. Remove shorting jumper across transmitter output and turn on power supply. 3. Remove jumper across CS. 4. Connect digital multimeter {20 vdc range) across relay coil terminals. (This de voltage is used to determine peaking of filter.) 5. Connect decade capacitance box across C2. Adjust capaci- tance aecade box to peak relay voltage. 6. Connect a second decade capacitance box across C1 in receiver. Adjust decade capacitance box until relay voltage is peaked. 5-14 This peak should not be less than 17.0 vdc. UNION SWITCH & SIGNAL 7. ffi Note values of capacitance decade boxes and duplicate those values with a combination of capacitors selected from list of TBD polyproplyene capacitors in Table 5-2. (Preferred method of capacitor selection is described in step 11 of Section 5.7.2.) reading. Be sure to duplicate or better peak Replace decade capacitance boxes with capacitors for C1 and C2. 5.7.4 Setting Transmitter Gain Before setting the transmitter gain, the BJORD-10 must be carefully tuned and connected in the test set up shown in Figure 5-2. The unit must be warmed up for at least 1/2 hour before setting the gain. However, warmup in the test circuit can be avoided by jumpering the transmitter to the receiver, Shorting Rl6, connecting a 400 ohm, 5 watt resistor to the relay terminals and applying power. 1. Connect decade resistor across lugs of R16 and set for 0.0 ohms. 2. Relay armature should be picked up. Monitor relay coil voltage with a digital multimeter. Apply joint resistor RJ 3. = 1.15 ohms as shown in Figure 5-2. If relay coil voltage is greater than 3.76 vdc, adjust R16 decade until 3.76 vdc is obtained. Replace decade with a 1/2-watt carbon resistor and proceed to shunting tests outlined in Section 5.7.5.2. 4. If relay coil voltage is approximately 3.76 vdc, replace R16 decade with a piece of bus wire and proceed to shunting tests of Section 5.7.5.2. 5.7.5 System Checks The system checks outlined in Sections 5.7.5.1 through 5.7.5.4 should be conducted after the transmitter and receiver adjustments have been accomplished. These system checks include a receiver sensitivity test, shunting tests, a receiver input current versus relay voltage test, and a receiver bandwidth test. 5-15 ffi UNION SWITCH & SIGNAL 5.7.5.1 Receiver Sensitivity Test The receiver sensitivity test is outlined in Section 5.4.2. 5.7.5.2 Shunting Tests 1. Reconnect BJORD-10 to test setup in Figure 5-2. 2. Turn on power supply; relay should be picked-up. 3. Temporarily place a 1.15-ohm shunt (R1) across simulated joint on transmitter side of bonds. away. 4. Relay should drop Remove R1; relay should pick up. Apply 200-foot and 10-foot shunt simulators across bonds, with 200-foot shunt across filter side of circuit. should remain picked up. Relay If not, check transmitter short- circuit current and be sure it is 5.8 to 6.0 amperes peakto-peak. 5. Apply two 35-foot shunts to circuit; relay should drop away. 6. Apply a short jumper across one bond only, relay should remain picked up. Leave this jumper across one bond and apply another jumper across other bond; relay should drop ·away. 5.7.5.3 Transmitter Output Characteristics Across Bond The transmitter output characteristics across the bond should resemble the spectrum as shown on the graph of Figure 5-3. This data was obtained using the test configuration shown in Figure 5-3 as follows: 1. The transmitter and receiver are wired in their respective positions across the insulated joints (simulated) as shown in Figure 5-3. 2. The transmitter and receiver are affixed at their nominal working parameters. The spectrum analysis was obtained from the signal developed across the low impedance winding of one of the bonds. HP3580. 5-16 The spectrum analyzer used was an APPENDIX· A SERVICE MANUAL 6215 PARTS LIST FOR BROKEN JOINT AND OVERRUN DETECTOR BJORD-10 November, 1981 A-81-250-2405-1 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC. Swissvale, PA 15218 UNIO~ SWITCH & SIGNAL A-1 BJORD Assembly (See Figure A-1.) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 * A-2 Quantity 1 2 1 2 1 1 1 2 2 14 2 1 4 4 4 12 32 16 8 16 12 12 1 1 1 1 3 8 8 8 2 2 Part Number Description R451401-7001 R451053-5201 M451401-7101 M451053-5501 M181829 J713333 J710029 J751130 J052566 J047733 J048172 R451401-7201 J052642 J047775 J480265 J052565 J047818 M029103 J730041 M029101 J525055 J047713 J078399 N451605-0301 N451605-0401 N451401-7301 J703302 A045749 J730044 A045525-0005 A045525-0007 J700651 Box Bracket, Support Cover Bracket, Mtg. Block, Terminal Holder, Fuse Fuse 3A, 3AG, Slo-Blow, 250V Grommet Ser, #10-32 x 5/8 Rd. Stl. Wshr, #10 Lk. Stl. Nut, #10-32, Hex. Stl. Cover, Front Ser. 1/4-20 x 1/2 Rd. Stl. Wshr. 1/4 Lk, Stl. Nut, 1/4-20 Hex. Stl. Ser. #1-0-32 x 1/2 Rd. Stl. Washer Nut, Clamp Terminal Nut, Binding Ser. #6-32 x 1/4 Rd. Stl. Washer #6 Shprf. Lk,· Stl. Bag, Parts Board, PC, Receiver Board, PC, Transmitter Board, Component Ty-Rap Wire #16, Blue Terminal, Pre-Insulated Wire, #16 PVC, Wht Wire, #16 PVC, Blk Clamp, Cable Item 7 is part of a vital safety circuit. Replace with a Littlefuse Co. #313003 Rev. 3/83 UNION SWITCH & SIGNAL NOTE: Items 23 and 27 thru 31 not shown. Item 7 is part of a vital saftey circuit. Replace with a Littlefuse Co. #313003 Figure A-1. Rev. 3/83 F45140~19 BJORD Assembly A-3 ffi EB. UNIO~ SWITCH & SIGNAL A-2 Transmitter Printed Circuit Board {See Figure A-2.) Reference Designation Quantity Part Number R1 R2 R3,4,5,18 19,20 R6 R7 , 11 , 12 , 1 3 R8 R9 R10 R14 R15 R17 R21,22 R24 R25 C1 C2 C3 C4 cs C6 C7 ca C9 C10 D1 D2,5,6 D3,4 V1 Q1 I 2 Q3,5,6 I Cl T1 T2 T3 1 1 1 N451605-0401 J720838 J720846 PCB, Transmitter Resistor, 100K 1/2W 5% Carbon II Resistor, 4 7K 6 1 J720882 J721255 J720883 J720892 J735321 J721212 J721065 J721189 J720881 J735519-0402 J720757 J270887 J706589 J709145-0444 J706664 J706120 J706568 J706552 J706625 J706419 J709145-0460 J700684 J726150-0079 J726031 J726150-0045 J735528 J731398-0040 J731291 J715022 N451030-4705 N451030-5503 N451030-4621 J714063 II Resistor, 1. OK II Resistor, 2.4K II Resistor, 10. OK II Resistor, 4.7K II Resistor, 33.2K II Resistor, 24. OK II Resistor, 470 Ohm II Resistor, 47 Ohm II Resi.stor, 1 O Ohm Resistor 0.2 Ohm SW 1% Wire Wounc Resistor 270 Ohm 1/2W 5% Carbon Resistor 220 Ohm Capacitor .01 Mfd 100 vdc Capacitor .04 Mfd 400 vdc Capacitor .1 Mfd 100 vdc Capacitor 1.0 Mfd 100 vdc Capacitor .082 Mfd 100 vdc Capacitor .1 Mfd 100 vdc Capacitor 10.0 Mfd 35 vdc Capacitor 47.0 Mfd 35 vdc. Capacitor .082 Mfd 300 VAC Capacitor 500 Mfd 25 vdc Diode, LVA462A, Zener Diode, 1N914A Diode, 1N5368B, Zener Varistor, V82ZA12 Transistor, 2N5962 Transistor, 2N4037 Integrated Circuit, 741 HC Inductor, Pot Core Inductor, Pot Core Inductor, Pot Core Lug, Turret 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 2 3 1 1 1 1 27 A-4 Description REC. BONDS ARE AC PROPULSION 1 OHM MINI N 451·003-0501 +10 0 ·10 iii -20 0 0 u > ::: > ID -30 0 ..J w ·40 > w ..J ...:::,w -50 .J ~ ID < -60 -70 c 2 0 -80 2 ~ 0 5 10 V1 15 20 25 30 35 40 45 FREQUENCY KHZ I 50 55 ~:c ~ Cl) G'5 2 -...J ,...)> Figure 5-3. Transmitter Output Spectrum Characteristics Across Bond ~ ffi UNION SWITCH & SIGNAL 5.7.5.4 Receiver Input Current VS. Relay Voltage The tracking relationship of the receiver input current vs. relay voltage should follow that shown on the graph of Figure 5-4. This data was obtained using the test configuration shown in Figure 5-2 as follows: 1. The output power of the transmitter was adjusted to provide the variable input current to the receiver. This was accomplished by temporarily replacing R16 in the transmitter circuit with a decade resistor. 2. Input current was measured using a Tektronix P6021 current probe and oscilloscope. Therms value was calculated from the peak-to-peak envelope. 5.7.5.5 Receiver Bandwidth Test The front end filter response characteristics of the receiver should follow the graph of Figure 5-5. This data was obtained using the test configuration shown in Figure 5-5 as follows: 1. The test signal used here was obtained from the tracking oscillator output of the HP3500 spectrum analyzer. This is a convenient source, as it is a sweeping oscillator which is necessary for this type of plot. 2. The MC-40 Mcintosh Amplifier is used to provide the necessary current to the 5-ohm receiver input. It is necessary to choose the MC-40 output taps nearest the 5 ohms required. 3. Spectrum analysis was obtained from that signal developed across the secondary of the front end transformer of the receiver. 4. The test signal level was adjusted for a O db reference at the carrier frequency. 5-18 18 17 16 15 -i 141 13 1. REFER TO FIG. 5-2 TEST CONFIGURATION 2. CURRENT CONTROL WAS R16 IN TRANSMITTER (DECADE BOX) 3. RMS CURRENT CALCULATED FROM PEAK TO PEAK .. ENVELOPE READING OBTAINED FROM CURRENT PROBE IREFER TO EQUIPMENT LIST, TABLE 5-11 12 u g w 11 c, 10 .J 9 ...< 0 > > ~ 8 a: 7 Ill 6 5 4 3 2 c z 0 0 100 200 300 400 500 600 700 - 800 900 1000 1100 1200 RECEIVER INPUT CURRENT IMA, rms) z ~ ~::i:: l1J' Cl) ci lJ1 z I _. '° )> ,- Figure 5-4. Receiver Input Current Versus Relay Voltage Characteristics E23 ffi UNION SWITCH & SIGNAL 0 RECEIVER FRONT ENO 5U TRACK osc OUT OUT ·1 H.P. 358!)A SPECTRUM ANAL YZER 1-------INPUT -2 BANDWITH .3 ,,m w > ~..., w ·5 -6 .7 ·8 .9 17.5 17.6 17.7 17.8 17.9 18.0 18.1 18.2 18.3 18.4 18.5 FREQUENCY KHZ Figure 5-5. 5-20 Receiver Input Filter Response Characteristics a: UNION SWITCH & SIGNAL 5.8 m POST-REPAIR INSPECTION Upon completion of any maintenance to the BJORD-10, an internal and external inspection should be performed as follows: 1. All components and material must agree with bill of material and must be correctly installed per appropriate assembly drawing. 2. All devices with polarity indicated must agree with markings on circuit board. This includes diodes, electrolytic capaci- tors, and transistors. Diode polarity is indicated by a band at its cathode, electrolytic capacitors by a"+" symbol, and transistors by arrangement of their lead wires. 3. All solder connections must be bright and free of flux. A dull, wrinkled appearance indicates a cold solder joint. 4. Transformers connected to circuit board with wires must agree with color code or numbering system, where appropriate. 5. Receiver and transmitter boards must be identified as such, and circuit board nomenclature, such as part number and serial number, must be correct and legible. 6. All mechanical fasteners, such as machine screws and nuts, must be secure and assembled in proper sequence according to drawings. 7. Wires to AAR terminals on top cover should be properly terminated with specified crimped connectors, and AAR nuts should be securely tightened. Each unit should be shipped with a bag of hardware consisting of 16 binding nuts (AAR) and 16 washers (AAR). 8. All internal wiring should conform to circuit diagram for color code. All wires should be free of abrasions and nicks in their insulation, and should have sufficient slack to permit disassembly without removing wires. In particular, wiring harness from transmitter to component board must allow free 180° hinging action of one board with respect to the other. 9. Exterior surfaces of case should be clean and free of dust or grime. 5-21/5-22