Transcript
IUNION SWITCH & SIGNALI~ A member of the ANSALOO Group 5800 ColJ)Orallt Drive, Plttsbu,gh, PA 15237
SERVICE MANUAL 6237
Installation, Operation, and Maintenance
TRU-11 CODE RESET UNIT
N451206-0201 N451206-0203 N451206-0205
October, 1984 (Revised June, 1992) c-6192-2450-1 MAC-6237
199Z
COPVAIGHT UNION SWITCH & SIGNAL INC. PRINTED IN USA .
AN SALDO Trasporti
REVISION INDEX
Revised pages of this manual are listed below by page number and date of revision. Revised text is indicated by a thick black line in the margin of the revised page.
PAGE NO.
I2A.IE
1-1 1-3 2-1 2-2 4-2 4-5 4-6 4-9 A-4 A-6
6/'ll 6/'ll 6/'ll 4/91 4/91 4/91 4/91 4/91
6/'ll 4/91
PAGENO,
CONTENTS SECTION GENERAL INFORMATION 1.1 SCOPE OF MANUAL 1.2 INTRODUCTION 1.3 SPECIFICATIONS
1-1
INSTALLATION 2.1 EQUIPMENT RACK MOUNTING 22 SHELF MOUNTING 2.3 UNIT OPERATING FREQUENCY CONVERSION
2-1
III
FUNCTIONAL DESCRIPTION
3-1
IV
MAINTENANCE AND TEST PROCEDURES 4.1 GENERAL 42 FIELD CHECKS 4.2.1 Recommended Test Equipment (or equivalent) 4.3 OPERATIONAL (SHOP) TESTS 4.3.1 Recommended Test Equipment (or equivalent) 4.3.2 Wiring and Time Period Test 4.3.3 Storage Discharge Sequence and RLYl Relay "On Tune" Test 4.4 COMPONENT (SHOP) TESTS 4.4.1 General 4.4.2 Series Tuned Circuits Test 4.4.2.1 Recommended Test Equipment (or equivalent) 4.4.2.2 Test Procedure 4.4.3 TRU-II Reset Unit Transformer Test 4.4.3.1 Recommended Test Equipment (or equivalent) 4.4.3.2 Test Procedure
4-1
II
APPENDIX A PARTS UST SHELF ASSEMBLY PAR1S LIST TRU-II CODE RESET UNIT PAR1S LIST TRU-II CODE RESET UNIT PCB PAR1S LIST
1-1 1-1
1-3
2-1 2-1 2-3
4-1 4-1
4-1 4-3 4-3
4-5 4-6
4-7 4-7
4-7 4-7
4-7 4-10
4-10 4-10
A-2
A-4 A-6
FIGURES AND TABLES FIGURE t TABLE
~
Figure 1-1 Figure2-1 Figure 3-1 Figure4-1 Figure4-2
Tru-II Code Reset Unit Installation Diagram Waveforms
Figure4-3
Series Tuned Circuits Test Set-Up
Figure4-4 Table4-1
Oscilloscope Trace Tuned Orcuit Specifications
Table4-2
Transformer Specifications
Figure A-1 FigureA-2
Shelf Assembly Tru-II Code Reset Unit
FigureA-3
Tru-II Code Reset Unit PCB
1-2 2-2 3-2 4-2 4-4
Test Set-Up Operational Test Waveforms
4-8 4-9
4-11 4-12 A-3 A-5 A-7
ii
SECTION I GENERAL INFORMATION
1.1
SCOPE OF tvfANUAL
This manual contains the installation, operation, and maintenance procedures for the following equipment: A. 100 Hz 1RU-II Code Reset Unit (Part No. N451206-0201) (see Figure 1-1) B. 91.67 /100 Hz (91.67 Hz) 1RU-II Code Reset Unit (Part No. N451206-0203) C. 91.67 /100 Hz (100 Hz) 1RU-II Code Reset Unit (Part No. N451206-02
I I I
i:r.
g g
TRACK
I
TRU-11
P>
1
l
I
1.... ~
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a
INPUT
BRN
+
L
IC3
I .Uipf 1 03 I 200V HG 47V JM 1N877B I 6111
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POO
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12v' -
-- re{ C6 a,.., 200V
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LY
HGJM 6111noo 24V
08
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I
1K
- - - - - - - -
_11~~006
2oov,- 1 I TL7
\NII\,
112W
.0061,1U9 71 C8
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R3
02
I TLa I
I
_______ JI
ORN
- - - - - - - - - - - - -I PN160BH I
TR
2.3
UNIT OPERATING FREQUENCY CONVERSION NOTE The conversion of a 91.67/100 Hz TRU-II Reset Unit from 91.67 Hz operation to 100 Hz operation or the conversion from 100 Hz to 91.67 Hz operation requires the unit to be shopped.
1. To convert to 91.67 Hz operation (Part No. N451206-0203), the lead wires to inductor L1 (see Figure 2-1) should be connected to terminals A and C. 2. To convert to 100 Hz operation (Part No. N451206-0205), the lead wires to inductor L1 (see Figure 2-1} should be connected to terminals A and B. 3. The name plate on the front cover should be turned (two-sided name plate) to reflect the correct operating frequency and part number. 4.
After a frequency conversion is complete, the TRU-Il Reset Unit must be tested to comply with the operational (shop) specifications.
6'237, p. 2-3
SECTION III FUNCTIONAL DESCRIPTION
The TRU-II Code Reset Unit, including printed circuit board identity, is shown in Figure 2-1. Pins 1 and 2 of the plug connector are the power input to the timer section of the TRU-II Reset Unit. The input is normally steady energy 110 V, 100 Hz (91.67 Hz) local signal power. During the coding mode, the local input is interrupted at the track code rate. Capacitor Cl and inductor L1 form a series tuned filter and in conjunction with transformer Tl, form a saturable transformer voltage regulator. Negative half wave rectification by diode 02 provides coded pulse power for code following relay RLY2 Resistor R3 and capacitor CS act as a filter circuit. Positive half wave rectification by diode 01 provides coded pulled power to the timer circuit which is primarily made up of resistor Rl, capacitor C2, DIAC 05 and the RLYl relay. These positive pulses charge up capacitor C2 to Vs, the DIAC switching voltage, at which time the capacitor is discharged and energizes the RLYl relay. The time period involved is in the 6-10 second range depending on code ontime as shown by Waveform A, Figure 3-1. The discharge of C2 occurs at the end of a code "on pulse" when relay RLY2 closes its back contact. The combination of R2 and O minimize the voltage rate of change experienced by the DIAC. C4 is a high frequency bypass capacitor. 03 is a Zener diode which prevents excessive voltage buildup across C2 during non-coding operation. Capacitor C6, diode 06, and the RLYl relay contact make up the analog storage part of the unit. The TRU-11 output is connected to the track relay and to the Reset Unit as shown. Positive TRU-II coded pulses charge capacitor C6 to the TRU-II peak output level via the back contact of the track relay and diode 06 as shown by Waveform B, Figure 3-1. When the timer determines that sufficient charge time has elapsed and the code input level just drops to zero, the RLYl relay energizes and discharges C6 across the relay providing a pickup assist in conjunction with the ordinary track relay coded input. Waveform C is an expanded part of Waveform B during capacitor discharge. Waveform D (same time scale as Waveform C) is the coded signal envelope at the TRU-II output. Waveform Eis a waveform of the track relay input current. Note the normal current waveform and the fill-in provided by the capacitor discharge provide sufficient energy to momentarily pick-up the track relay. When the back contact of the track relay is opened, the stick circuit of the "V" signal relay is broken and it deenergizes, resetting the track circuit to steady energy feed. RLYl and RLY2 are both mercury wetted relays with a contact life expectancy of about 20 billion operations. Note that with steady energy input, there is no relay action.
6237, p.3-1
v•
--
--
-ZENER - -LEV. 2
Vs
A
a-10 sec.
...
o...._------------------------------------------~t v
0-----------------------------'------------------t
VI-------------------------, c
oL------------------------------.c::;;..------------_.,t c
Figure3-1. Waveforms 6237, p.3-2
--,
Capacitor C6 is a high quality 5 µf mylar capacitor which is connected in parallel with the track relay. The TRU-II output is pulsed de with an average de pick-up level of 12V de. The capacitor charges to the peak TRU-11 output voltage which is about 60 V. Because of this high voltage, only 5 µf of capacitance is required. The dashed winding on inductor L1 applies to the 91.67/100 Hz TRU-II Reset Unit only. When these reset units are to be adjusted for 91.67 Hz operation (Part No. N451206-0203), the inductor connection is made to terminal C. When these units are to be adjusted for 100 Hz operation (Part No.N451206-0205) the inductor connection is made to terminal B. The adjustment taps on the secondary winding of transformer Tl (B, C, and D) are to adjust the time period to within the proper range.
6237, p.3-3
SECTION IV MAINTENANCE AND TEST PROCEDURES
4.1
GENERAL
Initial checks of the 100 Hz and 91.67/100 Hz TRU-II Reset Units consist of observing the track relay pickup during code reset. A Reset Unit suspected of being defective should be replaced with one known to be in working order. If
a unit is found to be defective, it should be shopped for repair or returned to US&S for repair or replacement. No TRU-II Reset Unit repairs should be attempted in the field. WARNING
EXTREME CARE SHOULD BE EXEROSED DURING "POWER ON" TESTS OF THE RESET UNIT. CONTACT WITH THE UNIT TERMINALS MAY RESULT IN PERSONAL INJURY.
4.2
FIELD CHECKS NOTE Since the TRU-II Code Reset Unit is always used with TRU-11 Unit (code overlay applications) its operation can be verified as part of the TRU-11 field check.
4.2.1
4.2.2
Recommended Test Equipment (or equivalent)
PEYJCE
SPECIFICATIONS
Analyzer
Simpson 260 (or equivalent, 20,000 0./V)
Field Check Procedure 1.
Check that the TRU-II Reset Unit and associated equipment is properly installed, including the condition and tightness of all terminal connections.
6'237, p. 4-1
lsow•v•~ I
FREQ METER
I
1N4006
WAVETEK MOD.116
l1N4006
I
I
STORAGE OCSILLOSCOPE CODER RELAY
:21
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:-:a
-
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;t
.'f"
....~
I
1P
tt)
I H AUDIO
080.
AUDIO AMP,
n
D
W-400 TRANS.
CODE RESET UNIT
1K (26W)
~-a--.. . 1
CH1 Cli2 EXT. SVNC.GND
~
7'
~ + 100K (1/2W)
NOTE: Do not Isolate 115V ac ground.
0
2.
Measure the voltage across the TRU-II Reset Unit local input socket terminals 1 and 2. (When applying mini-racks, measure this voltage between rack terminals L1 and L2.) When the track circuit is not shunted, the voltage should be steady energy 100 Hz (91.67 Hz) at about the 110 to 120V ac RMS range. When the track circuit is shunted, this input voltage level should be coded.
3.
To test the code reset unit, shunt its associated track circuit. At this time, the track feed shifts from a steady energy to a coded energy mode. On release of the shunt, the track relay should energize after a six to ten second time delay. The track feed should then shift to steady energy feed.
4.3
OPERATIONAL (SHOP) TESTS NOTE Shop tests must be performed on all TRU-II Code Reset Units sent to the shop for repair or spec. verification before returning them to service.
4.3.1
Recommended Test Equipment (or equivalent)
DEVICE
SPECIFICATIONS
Oscillator
Hewlett-Packard Mod. 200CD
Amplifier
Mcintosh 2100
Transformer
US&:S W-400, Type N451428-0101
Oscilloscope
Tektronix storage oscilloscope, Type 434
Probes (qty. 3)
"Times 10" probes
Frequency Meter
Hewlett-Paclcard Frequency Meter made up of H.P. 5300 measuring system and a
Voltmeter
5307A high resolution counter 0-150 V range ac
Oscillator
Wavetek, Model 115
Relay
Oare mercury wetted relay, 12 V, Model HGJM51111POO
Resistors and Diodes
Assorted, see Figure 4-1 NOTE
In making the test set-up shown in Figure 4-1, mount the relay vertically. Use only 5% tolerance resistors or better. Also be sure that the Code Reset Unit is mounted in the vertical position.
62:37, p. 4-3
t
A
7.1 to 10.0 s
47-53 V
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B
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60 to 82 ms -...;....;..1--.....
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1--
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1o to 20 v
...
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250ms
14310 166ms
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Figure 4-2. Operational Test Waveforms 6237, p. 4-4
4.3.2
Wiring and Time Period Test 1. Connect test instrumentation as shown in Figure 4-1. 2. Tum on all equipment and allow sufficient time for warm-up. Set the ac power frequency to 100 Hz (91.67 Hz) as required and the output level to 110 V RMS. 3. Tum the coder relay drive oscillator wave shape control to the square wave mode. Adjust its output frequency to 2.0 Hz (120 code). Adjust the square wave oscillator output level so that a positive 12 to 14 V pulse level is produced aaoss the coder relay as measured with an oscilloscope. 4. With the oscilloscope connected as shown in Figure 4-1, set its controls to storage mode, trigger to external, single sweep, positive slope and level to produce proper triggering. Set the scope vertical amplifiers to 20 V per division and set the horizontal time division control to 2 seconds per division. S.
Press the scope sweep button and observe the device output time period on Channel 1. This. time period should fall within the limits shown in Figure 4-2, Waveform A (7.1 to 10.0 s). The signal spike amplitude should range between 47 and 53 V.
6.
If the time period is outside of this range, adjust transformer TI secondary taps as follows: (1) Time period too long - move white wire from B to C or C to D as required. (2) Time period too short - move white wire from D to C or C to B as required.
7.
The analog input (scope channel 2) is shown in Figure 4-2, Waveform D.
6ZJ7, p.4-5
I
4.3.3
Storage Discharge Sequence and RLYl Relay "On Time" Test 1.
I
2. Press the reset button and observe the stored traces as shown within the desired enclosed portions of Waveforms Band C in Figure 4-2. The pulse width of Waveform B, which represents the RLYI relay "on time", should be within the 60 to 82 ms range. The residual voltage level remaining on the storage capacitor as shown by the pulse amplitude just before shut off should be within the 10 to 20 Y range.
I 3.
I
With all oscilloscope settings set as described in step 4 of Section 4.3.2, change the time division control setting to 50 ms per division position.
A 250 ms burst input signal follows the output signal by a time period which ranges between 143 to 166 ms as shown in Figure 4-2, Waveform C. NOTE Repeat this test six times to assure consistent performance.
6'237. o. 4-6
4.4
COMPONENT (SHOP) TESTS
4.4.1
General
Tests on individual subassemblies and components of the 100 Hz and 91.67 Hz TRU-II Reset Unit requires removing the cover and disconnecting the unit from all external connections. Make certain during reassembly that all parts and wiring connections are returned to their correct locations (see Figure 2-1). NOTE When assembly is complete, the unit must be subjected to the operational shop tests described in Section 4.3 before the unit is put back into service.
4.4.2
Series Tuned Circuits Test
4.4.2.1 Recommended Test Equipment (or equivalent)
DEVICE
SPECIFJCADQNS
Oscillator
Hewlett-Packard Mod. 200AB
Oscilloscope
Tektronix 434 two channel
Resistor Box
Decade Resistor Box 0-100 n, ±5%, Decade Resistor Box 0-10 KO, ±5%,
Amplifier
Mcintosh 2100
Frequency Counter
Hewlett Packard High Resolution Frequency Counter 5307A
Ohmmeter
Digital Ohmmeter, Fluke 80SOA multimeter
4.4.2.2 Test Procedure
1. Measure an inductor's de resistance value and compare it to the value listed in Table 4-1. 2. To perform an operational test on a tuned circuit. electrically isolate the circuit by disconnecting the lead wire shown in Table 4-1 and connect the tuned circuit (inductorcapacitor combination) into the test circuit shown in Figure 4-3. 3.
Adjust both oscilloscope trace lines so that their ground levels are on the middle horizontal line.
4.
Adjust the decade resistor to the required value shown in Table 4-1.
6237, p.4-7
OSCILLATOR
FnQUINCY COUNTII
SCON ...
ONO.
CHANNEL
1 ""1NPUT COMMON
CHANNEL
AMPLIFIER
2
c
SERIES DECADE RESISTOR
NOTE: EXTRA TURNS
ON INDUCTORS
Figure 4-3. Series Tuned Circuits Test Set-Up 6'237, p. 4-8
+
5. Adjust the input voltage to the level shown in Table 4-1. Maintain this level throughout the test. 6.
Adjust the oscillator frequency so that the oscilloscope trace appears as shown in Figure 4-4. The tuning point should be within the frequency range shown in Table 4-1.
NOTE
On unit N451207-1002 connect the full inductor winding for test purposes. If an inductor or capacitor is found to be defective, both must be replaced
since they are assembled and tested as a matched pair.
WHEN NETWORK IS PROPERLY TUNED , BOTH TRACES CROSS AT THE SAME POINTS
Figure 44. Oscilloscope Trace
6237, p. 4-9
·l.4.3
TRU-II Reset Unit Transformer Test
4.4.3.1 Recommended Test Equipment (or equivalent)
DEVICE Oscillator Multimeter
SPECWJCATIQNS Wavetek 115 F1uke8050A
4.4.3.2 Test Procedure 1.
Measure the transformer primary and secondary coil resistances and compare the readings to the values listed on Table 4-2.
2. To perform an operational test on transformer Tl, electrically isolate it by disconnecting the black lead wire on printed circuit board turret lug 2. Connect the oscillator output across terminals A and B of the primary coil. 3. Adjust the oscillator frequency to 100.0 Hz and the output level to 10.7V ac RMS. 4.
Using the multimeter, measure the signal voltage across terminals A and C of the secondary winding. The output signal should range from 25.7 to 27.9V ac RMS as shown on Table 4-2.
6237, p. 4-10
Table 4-1. Tuned Circuit Specifications
Specifications
Subassembly Unit Number N451207-1001
N451207-1002
Disconnect Lead Wire for Test
Yellow
Yellow
DC Resistance Start to Inductor Tap
so.6 0/55.6 o
55.o 0160.8 o
No tap
92.0 0/93.6 o
92.0 0/93.6 o
83.7 0/85.7 o
Level of AC Input Cht
30Vp-p
30Vp-p
AC Output Ch2
11.4-14.0 V p-p
11.4-14.0 V p-p
Resistance of Series Decade Resistor
11<.n
1 Kn
Min./Max. DC Resistance Start to End Min./Max. Tune Pt. LC Network Start to End Min./Max.
6237, p. 4-11
Table 4-2. Transformer Specifications
Specifications
I@nsfonner Number N4Sl039-4103
Resistance of Coil A (Primary)
2.60 n to 2.34 n
Terminal A to B Resistance of Coil B (Secondary)
14.7 n to 13.3 n
Terminal A to D Oscillator Out
10.7VRMS
Coil B Connections
Terminals A &: C
Output Voltage of Coil B
'l!S.7-27.9V RMS
6ZJ7, p.4-12
IUNION SWITCH & SIGNAL I[m1 A member of the ANSALOO Group 5800 Corporate Drive, Pittsburgh, PA 15237
SERVICE MANUAL 6237
APPENDIX A Parts List
TRU-11 CODE RESET UNIT
N451206-0201 N451206-0203 N451206-0205
October, 1984 (Revieed June, 1992) c-6192-2450-1 MAc-6237
ANSALDO Trasporti
COPVRIGHT 1902, UNION SWITCH & SIGNAL INC. PRINTED IN USA
SHELF ASSEMBLY PARTS LIST (See Figure A-1) DESCRIPTION
ITEM:NO.
US&SPART NUMBER
-
Shelf, Complete (91.67 Hz) Shelf, Complete (100 Hz)
N451207-1002 N451207-1001
1
Shelf
N451207-Q902
2
Inductor, 12 Hy (100 Hz Unit only)
N451039-4003
3
Inductor, 12 Hy (91.67 Hz Unit only)
N451039-4006
4
Transformer (Tl, see Figure 2-1)
9
Washer, 10 STL LI< MED
N451039-4103 ]792776 ]525074 ]047765 ]047733
11
Nut, 10-32 HEX STL
J048172
12
Wire, 20 PVC Black M258-30
A045505-0001
13
Ca pad tor, 0.2 µf 2000 V (Cl, see Figure 2-1)
]709145-0383
14
Printed Circuit Board (PCB)
N451522-8601
15
Screw, 10-32 x 1/2 IN RD
]052565
16
Washer, 10 FLT STL COML
J475077
17
Rubber Extruded CHAN
A075084
18
Gronunet,Rubberl/8ID
J075416
5
Bracket, Capacitor
6 7
Screw, 4-40 x 3/8 RHO STL Washer, 4 STL LI< MED
6237,p.A-2
.r----1---117
Drawing 0451207, Sh.10, Rev. 6
r-
1
I I I
Figure A-1. Shelf Assembly 6237,p.A-3
TRU-11 CODE RESET UNIT PARTS LIST (See Figure A-2) ITEM NO.
DESCRIPTION
-
Reset Unit, Complete (100 Hz) Reset Unit -0201 with Mounting Plate (item 1 below) Reset Unit, Complete (91.67 /100 Hz (91.67 Hz)T Reset Unit, -0203 with Mounting Plate (item 1 below) Reset Unit, Complete (91.67 /100 Hz (100 Hz)) Reset Unit -0205 with Mounting Plate (item 1 below) Mounting Plate Cover Body Plug, Eight Cont. Male Nameplate (100 Hz Unit only)
N451206-0201 N451206-0202 N451206-0203 N451206-0204 N451206-0205 N451206-0206 N451206-U02• N451207-1202 N451207-1302 J071878 M451496-8501
Screw, 10-32 x 3/8 ST Screw, 8-32 x 3/8 PNH STL Washer, 10 STL LK MED Washer, 8 LK S M1060-75 Nut, 8-32 HEX STL Shelf Assembly (100 Hz Unit only) Wll'e, 20 PVC Blue M258-30 Nameplate Wire, 20 PVC Red M258-30 Rivet, 1/8 Dia. AL POP Name Plate Wll'e, 20 PVC Green M258-30
JS<17266 J050985
Wire, 20 PVC Brown M258-30 Screw, 2 x 1/4 RHO Type Z Shelf Assembly (91.67 Hz only) Washer, #8 PL FLAT STL (100 Hz Unit only) Screw, 8-32 x 1/2 PNH STL (100 Hz Unit only)
A0455(&-0()03
.;..
-
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 23 24 27 28 29 30
I
•Not included with basic units -0201, -0203, -0206. Order mo1n1ting plate separately.
6237, p.A-4
US&SPART NUMBER
J047733 J047681 J048166 N451207-1000 A045500-0002 M451496-8502
A045500-0006 J490029 M451lll3-5202 A04550S-0004
J525007 N451207-1002 J047745 J701719
Figure A-2. Tru-II Code Reset Unit 6237,p.A-S
TRU-II CODE RESET UNIT PCB PARTS LIST (See Figure A-3) ITEM NO.
US&:SPART NUMBER
-
PCB, Complete
N451522-8601
C2 C3 C4
Capacitor, 50 µi lOOV de Capacitor, 0.15 µi Capacitor, 510 pf SOOY de Capacitor, 3 µi 200V de Capacitor, 5 µi 200V de Capacitor, .0047µ.f Resistor, 68 Kn, 1/2 W Resistor, 100 0, 1/4 W Resistor, 1 Kn, 1/2 W Diode, 1N4005 600V Diode, Zener SIL Thyristor, DIAC TRIG, 1N5761 Relay,SPDT24V de, 1 C Relay, 12V de, SPOT
1709145-0573 1702303 }709144-0040 1709034
cs C6 C7
I
DESCRIPTION
Rl R2 R3 01,2,4,6 03 05 RLYl RLY2 TL 1,2,6,7,8
-
Lug, Turret Wire, No. 22 Bare Tinned Cop.
6237, p. A..fJ
1706838 1709145-0130 1720850 ]735050 }720882 J723568 }726150-0148 }726258 }726153-()()67 }726153-00SO 1714159 A043183
_Jj R3n
~02LJ __ 01
;"""\. c: :n Drawing 45122
-n TL2 ~
'-ITlt
'-J
Sh. 86, Rev. 3
osn
t::t
Figure A-3. Tru-11 Code Reset Unit PCB 6237,p.A-7
