KP RELAY Description, Installation and Maintenance
Contents
1. pl s 21 3 Figure Al Relay Parts Location INOSIS V HOLIMS NOINN2. II Calibration Values for Standard Biased Type KP Relays Adjust Per Paragraph 4 7 1 2 Drop Away Milliamperes Closed Front Lum Contacts Full Drop Away N226848 N312193 N225785 191494 294846 215618 N296500 N321408 N380716 N191481 N374213 N240096 N381593 3623 p 26 aa UNION SWITCH amp SIGNAL D Table II Continued Special Sensitive Relays 2 2 Independent Contacts Approx 0 30 Inch Opening Adjust Per Paragraph 4 7 1 2 Pick Up Milliamperes Drop Away Milliamperes Closed Front Open Front Start Contacts Contacts Res Wkg 11 Part Code No 215619 12349 Upper 105 6 81 11 6 8 Lower 105 11 6 81 11 6 8 215620 12346 Upper 105 11 6 8 11 6 8 3 2 61 38 61 38 Special Single Contact Button 2F 2B Independent Contacts Approx 0 030 Inch Opening Adjust Per Paragraph 4 7 1 2 Pick Up Milliamperes Drop Away Milliamperes Closed Front Open Front Start Contacts Contacts Part Code Res Wkg 236321 12358 Upper Lower N236656 12359 Upper Lower N298221 Coils in N298263 Multiple N318066 Upper Lower Two relay units Pc N298221 are bolted front to front to form one dual relay Pc N298263 The tabluated calibration values in volts are used for each half with the coils connected in multiple This relay no longer available 3623 p 27 Q Y UNION SWITCH
3. UNION SWITCH amp SIGNAL 645 Russell Strect Batesburg SC 29006 SERVICE MANUAL 3623 KP RELAY Description Installation and Maintenance May 1985 An Ansaldo Signal Company C 1985 Union Switch amp Signal Inc Printed in U S A E DY UNION SWITCH amp SIGNAL REVISION INDEX Revised pages of this manual are listed below by page number and date of revision Page Date 25 5 85 Section I GENERAL INFORMATION 1 1 INTRODUCTION 1 2 DESCRIPTION 1 3 SPECIFICATIONS INSTALLATION e GENERAL e e 2 1 2 2 MOUNTING BASE 2 3 RELAY INDEXING 2 4 2 5 III FIELD MAINTENANCE INTRODUCTION 1 2 CLEANING a 4 IV Un mm Fd MAINTENANCE INTRODUCTION CLEANING INSPECTION TEST EQUIPMENT 00 Os Ut P CO ADJUSTMENTS CALIBRATION APPENDIX PARTS LIST TESTS AND CHECKS REPAIRS AND REPLACEMENT OPERATIONAL TEST RECEPTACLE SPRINGS RELAY INSERTION SERVICE REQUIREMENTS Contents PERIODIC PERFORMANCE TEST NN UNION SWITCH amp SIGNAL gt e 2 OO SS 22525 13 e 13 ee eo 13 e eee 13 9 10 00 we 13 oe 14 e 19 gt e e ea 23 606 29 Q gt UNION SWITCH amp SIGNAL SAFETY SUMMARY Safety precautions that must be observed when performing certain tests
4. amp SIGNAL Part Number N218749 N228492 N302263 3623 p 28 Table III Calibration Values for Special Biased KP Relays One Front Contact Only Pick Up amp Working Milliamperes Code Number Drop Away amp Full Drop Away Milliamperes Q UNION SWITCH amp SIGNAL 4 9 OPERATIONAL TEST 4 9 1 General Inspection a general inspection of the contacts shall be made after adjustment to see that they are properly aligned and meet squarely The relay calibration should then be checked Slight adjustment of the fixed contact members should be sufficient to meet the calibration b It should be noted that all lock washers are used where required and that they are fully compressed c The coil leads should be arranged so that they cannot vibrate into such a position as to interfere with operation of the contacts d Flexible connectors should be examined to see that they are formed to provide adequate clearances and are properly soldered tag should be marked with the code no and serial no of the relay together with data and inspector s initials This tag should be inserted in the bottom of the relay as shown in figure 4 f careful inspection should be made to be sure that all dirt and foreign matter has been removed form the mechanism paying special attention to air gaps and contact surfaces 4 9 2 Final Inspection a The front cover and back should be carefully assembled so tha
5. between the yokes and the end of each coil including one edge of the yoke mounting screws and also between the inside end of each coil and each side of the rear trunnion The consistency of the glyptal enamel should be watched carefully If it becomes stringy it is too thick and must be thinned using a special thinner A40172 If it is too thin it will run through and not perform the intended function of holding the coils firmly in place 3623 p 18 UNION SWITCH amp SIGNAL REL AY CONTACT FRAME YOKE COIL REAR T RUNNION OH XXXX Red Glyptal Enamel 40266 Figure 5 KP Relay Rear 4 7 ADJUSTMENTS 4 7 1 Contacts Contacts of various types of relays are adjusted differently to produce different characteristics This is accomplished by inserting the proper contact adjusting fixtures firmly into the air gaps at both ends of the relay see figure 6 thus holding the position of the rotor and then adjusting the fixed contacts so that their contact buttons just touch corresponding contact buttons on the flexible contact members Contact adjusting tool No M243059 has been specifically designed for this purpose In no case shall flexible contact members be adjusted to align contacts The contact adjusting fixtures to be used the deviation permitted from perfect contact adjustment the heat treatment required and the contacts to be adjusted with the adjusting fixtures in a given position are giv
6. or break adjustments slightly altered in order to increase the normal pick up and decrease the reverse pick up until the above specification is met When recalibrating the above type of relay only sufficient alteration or correction of contact adjustments should be made to directly reproduce the above calibration without going through the basic procedure 3623 4 UNION SWITCH amp SIGNAL b 1 3 1 5 KP Biased Type Relays 2 Normal 2 Back Independent Contacts Contact Opening Approximately 0 030 Inch Relay Coils Milliamperes Part Code Working Drop Away Number Number Max Min N225785 23456 55 15 55 15 294846 12367 45 N215618 12348 N296500 12379 N191481 57890 N240096 12340 The make or break adjustement position of all four contacts of relays in the above table is the midstroke position of the armature With armature in midstroke position all four contacts should be just on the point of making If there is more than approximately 0 001 inch opening just a visible gap it should be reduced until the gap is visible This adjustment should be produced on all four contacts In no case should either front contact close before both back contacts open They should either just make at the same point or be slightly open Tool N243000 is used to lock the armature in the mid position for adjustment of the above relays UNION SWITCH amp SIGNAL 1 3 2 Mechanical The followin
7. switch 51 to Normal Adjust DC power supply output control to charge relay see table I Gradually reduce current to zero Then reverse polarity and gradually increase current to determine pick up value The minimum pickup and working values obtained in steps i and m above should be as nearly alike as possible Test concluded Disconnect test circuit and return relay to its original location Q UNION SWITCH amp SIGNAL SECTION IV SHOP MAINTENANCE 4 1 INTRODUCTION This section provides the information necessary to perform shop level repairs of the KP relays covered in this manual general relays arriving at the shop for repair have been checked at the field and have been found to perform unacceptably 4 2 CLEANING Before recalibration all foreign matter should be removed from the interior of the relay particular attention being paid to the contacts and armature stop pins Follow up with procedure given in paragraph 3 3 4 3 INSPECTION Inspect the relay for signs of physical damage such as cracked or broken 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 for obvious physical damage 4 4 TEST EQUIPMENT The following test equipment is required to perform the tests presented in this section Tool to Tool Armature N243000 Tool to Tool Armature N243001 Too
8. the flexible heel connectors to their frame supports by means of eyelets and then solder The solder should not run beyond the ends of the supports 11 soldering on these relays should be done using a non corrosive solder flux It is recommended that solder with a resin 5 core be used Immediately after a solder connection is made the soldered area should be cleaned with a clean dry cloth moistened in alcohol With the permanent magnets removed the armature should take a central position with respect to the pole faces If the armature s off center the brass members to which the heel connectors are attached should be bent until the armature takes a central position with respect to the pole pieces The bending should be distributed among all members no case should the heel connectors themselves be bent Before soldering form each coil lead into a loop as follows Where the lead enters the coil bend it away from the coild end of a 1 8 inch radius and then form it in a circular loop about 1 4 to 3 8 inch in diameter as shown in figure 4 H it 1 4 dero 8 RADIUS Figure 4 Coil Lead Forming After the relay is assembled but before the application of the permanent magnets and before heat treating apply red glyptal enamel A40266 to the back of the relay in eight places as shown if figure 5 in order to prevent coil movement under vibration conditions The enamel should be applied on the outside end of both coils
9. 10 inch transfer opening between the normal and reverse contacts Tool N243002 is used to lock the armature in the correct positions for adjustment of the above relays 1 3 1 3 KP Stick Type Relays 4 Normal 4 Reverse Non Independent Contact Contact Opening Approximately 0 026 Inch Milliamperes Relay Coils Pick Up Ohms Location Res Min Code Number Part Number N347480 57 57 N371940 74 Calibration values apply for both Normal and Reverse Pick Ups The make or break adjustment positions of both Normal and Reverse contacts of relays in above table are 0 015 inch on either side of midstroke position This provides a 0 030 inch transfer opening between the normal and reverse contacts Tool N347547 is used to lock the armature in the correct positions for adjustment of the above relays 3623 p 3 Q UNION SWITCH amp SIGNAL 1 3 1 4 Special KP Stick Type Relays With Off Center Adjustment 2 Normal 2 Reverse Independent Contacts Contact Opening Approximately 0 040 Inch Pick Up Milliamperes Normal Reverse Relay Coils Clockwise Counterclockwise Part Code Ohms Number Number Location Res Max Min Max Min N231412 12357 Upper 75 20 0 15 0 12 6 9 4 33 29 4 21 6 18 9 13 1 This relay is normally calibrated by first giving it the same mechanical contact adjustments as the standard stick type relay with 2N 2R independent contacts Then the 0 005 inch off center make
10. 25 N191429 o O FW WW C CO CO CO ND NNE Frame Frame Rotor Comp Rotor Comp Rotor Comp Rotor Comp Coil Coil Coil Coil Coil Coil Coil Yoke Screw Washer 6PS LK Nut Permanent Magnet Pivot Bracket Pivot Bracket Comp Relay Ref 3623 Pe Al UNION SWITCH amp SIGNAL Parts List for KP Relays Continued Used on Relay Ref Description Nut 11 M242271 M273771 Screws M248353 Cover M248362 Cover M248364 Cover M248365 Cover M248354 Cover M248357 Cover M248358 Cover M248361 Cover M248368 Cover M248371 Cover M294844 Cover Back M296501 Cover M347549 Cover M371941 Cover J047081 Gasket Rubber J776373 Cover Front Clear J047355 Gasket Molded Rubber J480006 Nut 4 40 Hex Steel J522142 Screw 4 40 Hex Steel J070883 Eyelet Brass J062742 Plate Alum Name J075599 Tag with Opq Acetate M233946 Washer M233947 Washer M317304 Washer M279717 Springs J525024 Screw 4 40 X 3 16RDH Par 3623 2 5 9 5596 15 16 6 11 EU il No oL 0 i ak ae TRU 8 26 3 E A n ji p 20 sf ss im 22 23 24 2 1 13 itx 3
11. 462 N191462 N236320 N236320 N191462 N191462 Relay N341621 and N381212 use 3623 p 15 Q UNION SWITCH amp SIGNAL 4 6 3 3 Special Biased Type Relays Part No of Relay Piece Number Complete Rotor Assembly N218749 N191489 N228492 N228493 N302263 N302536 4 6 4 Assembly Procedure Place the contact frame in position on inspection fixture No T35202 and adjust the contact members both vertically and horizontally so that the contact buttons just touch the spacer in the fixture Contact adjusting tool N243059 has been specially designed for this purpose Stamp the piece number of the relay to be assembled on the top rear surface of the contact frame Assemble the front trunnion bracket to the contact frame as shown in figure 3 Observe that the screw heads do not extend beyond the front of the contact frame Assemble the rotor coils and yokes to the contact frame as shown in figure 3 without fastening the yokes tightly If the fit between coils and yokes is too tight the coil notches should be filed just enough to avoid a force fit Place the rear trunnion bracket in position and with it held firmly against the contact frame observe by means of a dial indicator that the rotor has from 0 005 inch to 0 010 inch end play between the front and trunnions the end play is less than 0 005 inch it may be increased by applying spacer washers under the rear trunnion bracket as shown in figure 3 Also observe that
12. A INSERT TOOL INTO TOP amp BOTTOM AIR GAP OETAIL A Figure 6 Adjustment Fixture Placement UNION SWITCH amp SIGNAL 6 After contact adjustment each relay should be calibrated per paragraph 4 8 and heat treated at 240 F for six hours or at 2009F for fifteen hours with the rotor in the normal clockwise position The heat treatment should then be repeated with the rotor in the reverse counterclockwise position The contact adjustment should then be checked and if it is necessary to change the adjustment of any contact more than 0 002 the relay should be heat treated again and rechecked 4 7 1 2 Standard Biased Type Relays ae Relays with 2F and 2F independent contacts adjusted to make in midposition to provide 0 030 inch compression and 0 030 inch contact opening and no overlap in midposition Calibrate per table II A C and 1 Insert contact adjusting tool part number 243000 to hold the rotor in midposition 2 Adjust all normal contact members per paragraph 4 7 1 3 For inspection purposes all contacts should be within 0 001 inch of perfect adjustment 4 After all contact adjustments the rotors of all relays should be held in the clockwise position using wood wedges and heat treated at 2409 F for six hours or at 2009F for fifteen house and then reheat treated with the rotors in the counterclockwise position If it 1s necessary to change the adjustment of any contact more than 0 002 in
13. aken on pick up as follows Start Pick up close front contacts and Working Full Stroke Two points are taken on drop away as follows Drop away open front contacts and Full Drop away The pick up and drop away calibration values should be checked for both front contacts and must fall within the limits specified in table II the start value on pick up 15 too high the magnets should be further demagnetized with a higher value of alternating flux If the start value on pick up is too low the magnets should again be fully charged and demagnetized with a smaller value of alternating flux 3623 p 23 S J UNION SWITCH amp SIGNAL 4 8 4 Special Biased Type Relays The pick up drop away values must be within the limits shown in table III pick up the amount of current required to close the front contact pick up value must also complete the stroke working value Likewise on drop away the amount of current required to open the front contact drop away value must also complete the stroke full drop away value case this action cannot be obtained the stops for the load springs may be adjusted to contact the load springs nearer the free end In no case should they be closer than 1 32 to the free end of the load springs 4 8 5 Calibration Tables KP relays calibration should be checked by the usual calibration equipment The calibration values should be taken on each coil separately in accordance with the accompanying
14. aken up When off center positions are being checked care should be taken that the top and bottom tools are so inserted as to provide the same direction of off center locking in order to prevent damage to the p vots The armature positions at which the contacts should just make or break should be the basis for all contact adjustments With the armature locked in position contacts should be adjusted to the point of making i e between a barely visible gap to the point of just making contact 4 5 2 Midstroke Adjustment Relays having the midstroke adjustment can have all contacts checked with one setting of the tools 4 5 3 Off Center Adjustment When off center adjustments are involved one setting of the tools will serve for checking the normal contacts after which the same tools can be used for checking the reverse contacts by reversing the prongs of the tools in the magnetic gaps to lock the armature on the other side of center position 4 6 REPAIRS AND REPLACEMENT 4 6 1 Dissassembly Dismantle the relay only to the degree necessary to complete repair Refer to the parts list for part information and location of parts In general to dismantle the KP relay proceed with the following sequence Remove relay cover b Remove disassemble relay components as required Remove contacts as necessary 3623 p 14 4 6 2 Reassembly Q UNION SWITCH amp SIGNAL Reassembly is accomplished generally in the reverse order of disassem
15. are cross referenced by test and paragraph number The specific WARNING 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 common safety practices Q UNION SWITCH amp SIGNAL SECTION I GENERAL INFORMATION 1 1 INTRODUCTION This service manual provides service information for style KP relays The style KP designation includes a group of direct current two position polar type relays The fundamental design physical dimensions and general appearances of this entire group are identical but the basic adjustments contact combinations coil resistances and calibration values are furnished in various combinations for different applications Because of the special fixtures required in the assembly of these relays t is recommended that they be returned to the factory when major repairs involving replacement of parts are required However where facilities are available to handle major repairs reference should be made to that particular section covered in this service manual 1 2 DESCRIPTION 1 2 1 General All KP relays are individually housed in molded bakelite cases with all operating parts fully enclosed and sealed All contacts are visible through the front cover glass The contact members are molded permanently in bakelite By means of basic magnetic adjustments made during manufacture either of tw
16. bly following paragraphs provide additional instructions to be followed during reassembly of this relay relay Upon completion of reassembly calibrate the relay as directed in paragraph 4 8 4 6 3 Rotor If the roter has been damaged bending of springs it should be replaced Do not overtighten or force parts when reassembling a or requires restoration other than by minor Ordering references for complete rotor assemblies are given in this section for each type of relay Before it is assembled to the relay each complete rotor assembly should be inserted in inspection fixture tool No 35154 and the adjustment of the contact springs and flexible connectors checked and if necessary adjusted If any change of more than 0 005 inch is necessary the rotor should be adjusted and baked at 240 for six hours or at 2009F for fifteen hours and then rechecked after baking 4 6 3 1 Stick Type Relays All relays with 4N 4R contacts use rotor N191461 except N341621 and N381621 use rotor N191382 rotor N341619 4 6 3 2 Standard Biased Type Relays Relay Piece Number This relay is no longer available N191481 N191494 N215618 N215619 N215620 N225785 N226848 N236321 N236656 N240096 N294846 N296500 N298221 N298263 N305256 N312193 All relays with 2N 2R contacts Part No of Complete Rotor Assembly N191462 N191462 N191462 N215621 N215621 N191462 N191462 N236320 N236320 N191462 N191
17. ch after heat treatment the relay should be reheat treated and rechecked 4 7 1 3 Special Biased Type Relays With the adjusting tools part number 243003 in position the contacts should just touch within 001 and there should be approximately 0 005 clearance between the load springs springs wihout silver buttons and their stop members The position of the stops should be such that they will contact the load spring approsimately 1 8 inside of the end of the spring After contact adjustment the rotors of all relays should be held in the clockwise position using wood wedges and the relays heat treated at 240 F for six hours or at 200 F for fifteen house and then reheat treated with the rotors in the counterclockwise position If it is necessary to change the position of any contact more than 0 002 after heat treatment the relay should be reheat treated and rechecked Q UNION SWITCH amp SIGNAL 4 8 CALIBRATION 4 8 1 Permanent Magnet Calibration and Adjustment Permanent magnets should be assembled on the relay with the poles marked N to the right as viewed form the front of the relay The poles marked N should attract the end of a magnetic compass which points toward geographic South b Relay calibration is finally determined by adjusting the strength of the permanent magnets pair of magnets should be placed over the coils of a relay to check if they seat squarely against the yokes They should then be charged to f
18. e is once or twice a year initially with subsequent checks gauged by results of previous records 3623 p 9 Q UNION SWITCH amp SIGNAL 3 4 2 Test Procedures Test the operating characteristics of the KP relays as follows 3 4 2 1 Recommended Test Equipment NOMENCLATURE PART MODEL TYPE NO Power Supply 0 40 Vdc HP62058 or equivalent Digital Multimeter two required HP3435A or equivalent DPDT Double pole double throw Switch 3 4 2 2 Biased Relay Test Procedure Connect the circuit as shown in figure 2 and proceed as follows Set Ml to appropriate current range Set M2 to appropriate voltage range Set DC power supply to appropriate output range Set switch S1 to Normal Turn DC power supply on Observe 1 Current Monitor and adjust DC power supply output control to charge the relay Charge equals four times pick up or working see table II or III Gradually reduce current until front contacts open This 1s the dropaway value Further decrease current if necessary until pins touch pole pieces This is the full dropaway value Momentarily open circuit then close it and gradually increase current until relay closes its front contacts This is the pick up value Further increase current if necessary until the armature stop pins touch the pole pieces This is the working value Test concluded Disconnect test circuit and return relay to its original location UNION SWITCH a
19. en in the supplementary specifications covering each type of relay For stick type KP relays the contacts which are compressed when the rotor is turned to the clockwise position as viewed from the front of the relay are designated normal contact and the contacts which are compressed when the rotor is turned counterclockwise asre designated reverse contacts For biased type KP relays the contacts which are compressed when energy is applied to turn the rotor to the clockwise position as viewed from the front of the relay are designated front contacts and the contacts which are compressed when no energy is applied to the relay rotor in the counterclockwise position are designated back contacts Q UNION SWITCH amp SIGNAL 4 7 1 1 Stick Type Relays a Relays with 4N and non independent contacts adjusted to make at 0 025 off center to provide 0 050 contact opening and 0 030 contact compression Calibrate per table I A l Insert contact adjusting tool part number 243001 in air gaps with the stencilled members toward the front of the relay to hold the rotor position 0 025 off center in the clockwise direction Adjust all normal contact members per paragraph 4 7 1 Reverse the contact adjusting tool so that the stencilled members are toward the rear of the relay to hold the rotor position 0 025 off center in the counterclockwise direction Adjust all reverse contacts per paragraph 4 7 1 For inspectio
20. g mechanical specifications are common to all KP relays covered in this manual UNION SWITCH amp SIGNAL S SECTION II INSTALLATION 2 1 GENERAL The KP relay is plug connected for quick and easy replacement Relays are keyed to plug connectors to prevent plugging the relay into an incorrect position Various size mounting racks are available for plug in mounting on a horizontal shelf Relays are wired from the rear on solder terminals The relay s are plugged into connectors on the rack and can easily be removed for maintenance or replacement 2 2 MOUNTING BASE Bar supports are available for mounting up to seven KP relays ona rack This support is arranged for all circuits to be wired directly to the relay plug connector solder terminals The KP relay is inserted into plug connectors and secured with two hinged lock plates 2 3 RELAY INDEXING Means are provided in the relay case and plug connectors to prevent the plugging in of a given relay into the wrong position A combination pin plate is associated with each pair of plug connectors and contain five pins in various combinations Each separate piece number relay has an individual combination assignment Slots are milled in the base of each relay to match this assignment Accordingly none but the correct relay can be plugged into a given connector position having slots matching pin positions The numbers remaining on the base of the relay after slots have been cut identify the c
21. l to Tool Armature N243002 Tool to Tool Armature N347547 Adjusting Tool N242994 Contact Adjusting Tool N243059 Spring Gauge N320728 Inspection Fixture Tool T35154 Inspection Fixture Tool T35202 4 5 TESTS AND CHECKS 4 5 1 Fixed Contact Elements Unless major repairs are necessary the original calibration values of style KP relays may be obtained by slight adjustment of the fixed contact elements Contact adjustment tool M243059 has been specially designed for this purpose All bending of contact elements should be restricted to the heavier semi rigid member The straight flexible contact springs must not be bent 3623 p 13 5 gt 7 UNION SWITCH amp SIGNAL All adjustments should be made in such manner as to leave the minimum amount of tension or fiber stress in the fixed contact members by slightly overstressing in the direction of the adjustment and counter stressing to the final adjustment position This method minimizes any tendency toward further change in service Special armature positioning tools references for which are given in the calibration tables are inserted in the magnetic gaps to lock the armature n the correct positions for checking or adjusting the contacts Leaf gauges should not be used for this purpose Two armature positioning tools one for each end of the armature should be inserted through the magnetic gaps into the coil spools and pressed firmly in position until all armature motion is t
22. mp SIGNAL v M1 CURRENT MONITOR 1 2 2 VOLTAGE MONITOR RELAY UNDER TEST NORMAL 1 2 Test Circuit 1N 2R 1R 2N 1 c LOOKING AT pme 2P 4 FRONT OF UNIT 2 2 4P 3P 4N 4Rc 3N B Terminal Identification Figure 2 KP Relay Test Circuit Q UNION SWITCH amp SIGNAL 3 4 2 3 proceed ae b h 1 1 The KP Stick Relay Connect relay test circuit as shown in figure 2 and as follows Set Ml to read in the appropriate D C ma range Set M2 to read in the appropriate D C voltage range Set the D C power supply to the appropriate output range Set switch S1 to Reverse Turn the D C power supply on Observe Ml Current Monitor and adjust DC power supply output control to charge the relay Charge equals four times pick up or working see table I Relay should energize in the reverse position Adjust DC power supply output control to gradually decrease current reading on to zero Reverse contacts should remain closed Set switch 51 to Normal Adjust DC power supply output control to gradually increase current until relay armature picks up and normal contacts close Current monitor 1 and voltage monitor M2 should indicate the minimum pickup and working values indicated in table I Adjust DC power supply output control to decrease current reading on Ml to zero Normal contacts should remain closed Set
23. n Field maintenance covers periodic inspections and performance tests 3 2 SERVICE REQUIREMENTS If service field values are given in service instructions covering the equipment or system in which the KP relays are used those recommendations should be followed In the absence of such values it is suggested that relays having a pick up greater than 110 of the value shown in the tables of this service manual or a drop away less than 67 of the tabulated value be taken out of Service for recalibration 3 3 CLEANING For general cleaning a small dry fine bristled camel s hair brush may be used Contacts and stop pin surfaces may be cleaned by brushing lighly with a clean fine bristled brush moistened with clean denatured ethyl alcohol and then drying immediately with a strip of clean lintless cotton tape 3 4 PERIODIC PERFORMANCE TEST 3 4 1 General These relays are normally used in circuits provided with spark protective features accordingly contacts should require little special attention Periodic performance checks should include check of calibration values at regular intervals b Observation of the general condition of relay operating parts visible through the cover glass to make certain that the spark protective features are functioning The sensitive biased relays such as are used in code line circuits should have more frequent calibration checks than the less sensitive stick type relays Recommended rat
24. n purposes all contacts should be within 0 002 of their correct position After contact adjustment each relay should be calibrated per paragraph 4 8 and heat treated at 2400 for fifteen hours with the rotor in the normal clockwise position The heat treatment should then be repeated with the rotor in the reverse counter clockwise position The contact adjustment should then be checked and if it is necessary to change the adjustment any contact more than 0 002 the relay should be heat treated again and rechecked b Relays with 2N and 2R independent contacts adjusted to make at 0 005 off center to provide 0 010 travel between the opening of the reverse contact and the making of the normal contact and to provide for 0 030 contact compression and 0 040 contact opening Calibrate per table I B l 3623 p 20 Insert contact adjusting tool part number 243002 in air gaps with the stencilled members toward the front of the relay to hold the rotor position 0 005 off center in the clockwise direction Adjust all normal contact members per paragraph 4 6 4 a Reverse the contact adjusting tool so that the stencilled members are toward the rear of the relay to hold the rotor position 0 005 off center in the counterclockwise direction Adjust all reverse contacts per paragraph 4 7 1 For inspection purposes all contacts should be within 0 002 of their correct position UNION SWITCH amp SIGNAL D AIR GAPS DETAIL
25. o different types of relays operation are provided namely stick or biased The armature of a stick type relay is operated into alternate positions clockwise or counterclockwise by opposite polarities and remains in the last operated position when the coils are deenergized The armature of a biased type relay is operated clockwise closing the front contacts by normal polarity and returns to the counterclockwise or biased position opening the front contacts when deenergized Since the armature remains in the counterclockwise position when reverse polarity is applied the biased relay functions as a sensitive biased relay Basic magnetic adjustments in combination with various contact assemblies also govern the wattage requirements of individual relays will be noted from the calibration tables that the operating levels range from approximately 150 to as low as 5 milliwatts Q UNION SWITCH amp SIGNAL 1 2 2 Coils KP relays have two coils which may be used either independently or in combination to suit requirements In addition any given relay of either stick or biased type of fixed wattage can be furnished in a range of coil resistance from a fraction of an ohm to approximately 4 000 ohms per coil to provide for various circuit requirements 1 2 3 Contacts Contacts are permanently molded in bakelite and are visible through the front cover glass The contact arrangements available provide for a multiple of ci
26. ode combination for the relay 2 4 RECEPTACLE SPRINGS Each plug connector contains a number of receptacle springs which engage the relay fingers To insure proper operation of the relay the receptacle springs may be checked as follows ae With the relay in position it should be checked visually to see that each relay finger extends to or beyond the edge of its receptacle spring thus providing an adequate contact b With the relay removed from the plug connectors a spring pressure check should be made on each receptacle spring For a receptacle spring having proper pressure a force of a least two 2 ounces should be required to remove a polished metal finger 1 64 in thick inserted betweeen the spring and the bakelite Spring gage N320728 was specially designed for this purpose 3623 p 7 UNION SWITCH amp SIGNAL 2 5 RELAY INSERTION The KP relay is inserted into the plug connector and secured with two hinged lock plates Figure 1 shows a typical KP relay installation RH LH CONNECTOR CONNECTOR LOCK PLATE PIN GUIDE RELAY GUIDE KP STYLE RELAY MOUNTING BAR SUPPORT Figure 1 Relay Installation 3623 p 8 Q UNION SWITCH amp SIGNAL D SECTION III FIELD MAINTENANCE 3 1 INTRODUCTION The necessary periodic preventive maintenance procedures which must be performed to ensure continuous proper and efficient operation of the KP relays covered in this manual are provided in this sectio
27. rcuit applications 1 3 SPECIFICATIONS The following paragraphs provide the electrical and mechanical specifications of the KP relays covered in this manual 1 3 1 Electrical Relay electrical specifications are tabulated in the following paragraphs 1 3 1 1 KP Stick Type Relays 4 Normal 4 Reverse Non Independent Contact Contact Opening Approximately 0 050 Inch Milliamperes Relay Coils Pick Up Part Code Ohms Number Number Location Res Max Min 45 90 N191493 45 45 N217122 14 14 N191500 Calibration values apply for both Normal and Reverse Pick Up The make or break adjustment positions of both Normal and Reverse contacts of relays in above table are 0 025 inch on either side of midstroke position Tool N243001 is used to lock the armature in the correct positions of adjustment of the above relays UNION SWITCH amp SIGNAL 1 3 1 2 KP Stick Type Relays 2 Normal 2 Reverse Independent Contacts Contact Opening Approximately 0 040 Inch Milliamperes Relay Coils Pick Up Code Ohms Number Location Res Min 45789 56780 20 30 20 20 30 20 1070 5 3 1070 5 3 Calibration values apply for both Normal and Reverse Pick Ups Part Number N191499 N220821 The make or break adjustment positions of both Normal and Reverse contacts of relays in above table are 0 005 inch on either side of midstroke position This provides a 0 0
28. s to determine the full drop away value Open the circuit momentarily and then close it and gradually increase the current until the relay closes its front contacts to determine the pick up value Further increase the current if necessary until the armature stop pins touch the pole pieces to determine the working value Biased relays return to the counterclockwise position when energy is removed and will not pick up when reverse energy is applied 3623 p 24 UNION SWITCH amp SIGNAL b 5 Table I Calibration Values for Stick KP Relay Values 4N 4R Non Independent Contacts Approximately 0 050 Opening Adjust per paragraph 4 7 1 1 Pick Up One Coil Coil Resistance Ohms Milliampers Pc No Code No N191362 N294847 N191493 N217122 N231072 N191500 N314119 N335380 N341621 N381212 2N 2R Independent Contacts Approximately 0 040 Opening Adjust per paragraph hets laD N225784 N191499 N262433 N292335 N220821 337612 Two normal and two reverse contacts removed Magnets and polarity reversed B Special Relay Off Center Adj 2N 2R Independent Contacts Approximately 0 040 opening See paragraph 4 8 2 Adjust Per Paragraph 4 7 1 1 b Pick Up One Coil Code Coil Resistance Ohms Counterclockwise N231412 15 9 1 13 22 5 85 3623 25 D UNION SWITCH amp SIGNAL Table
29. t all gaskets lie smoothly and are compressed sealing the relay tightly Observe that the gasket does not extend beyond the edges of the relay b After sealing the relay should be examined through the cover to see that contacts flexible connectors and coil leads have not been misplaced since calibration c A final check of relay calibration should be made UNION SWITCH amp SIGNAL INC A member of the ANSALDO Group 5800 CORPORATE DRIVE PITTSBURGH PA 15237 D R SERVICE MANUAL 3623 Parts List KP RELAY Part Numbers N220821 N191481 N191493 N191499 N191500 N215618 N371940 N294846 N225785 N296500 N347480 N231412 N217122 N240096 Appendix A January 1982 Rev May 1985 120044 C 7 89 25 861 3 COPYRIGHT 1989 UNION SWITCH amp SIGNAL INC PRINTEO USA Reference Number N191481 N191493 N191499 N191500 N215618 N217122 aj d C2 OW gt N220821 225785 231412 240096 294846 296500 347480 371940 MAMA Relay Part Parts List For KP Relay No Contacts mm Q D m t Domo m I Independent Contacts N Non Independent Contacts Parts List for KP Relays See Figure Al UNION SWITCH amp SIGNAL Coil Ohms Used on N191363 N191480 N191462 N191461 N191382 N347479 N220783 N191479 N226572 N191498 N321410 N231411 N248743 N191385 N286398 J047662 M151836 M191464 M2413
30. tabulations For normal polarity apply positive battery to the left hand terminal of either coil This will rotate the armature of any KP type relay clockwise For reverse polarity apply negative battery to the left hand terminals This will rotate the armature counterclockwise The stick relay should first be charged at reverse polarity to approximately four times maximum pick up value and the current then gradually reduced to zero Reverse the polarity then gradually increase the current until the armature moves to the clockwise position to determine the normal pick up value The armature should go to full stroke at this same value and should remain at full stroke when the relay is deenergized The relay should then be charged at normal polarity by increasing the current to approximately four times maximum pick up value Then the current should be gradually reduced to zero Reverse the polarity and gradually increase the current until the armature moves to the countercloskwise position to determine the reverse pick up value The armature should go to full stroke at this same value and should remain at full stroke when the relay is deenergized The biased relay should first be charged at normal polarity to approximately four times maximum pick up value and the current then gradually reduced until the front contacts open to determine the drop away value Further decrease the current if necessary until the armature stop pins touch the pole piece
31. there is at least 0 015 inch clearance between the rotor hub and each coil as called for in figure 3 Insert adjusting tools No N242994 in the slots provided at each end of the contact frame Hold the yokes firmly against these tools and fasten yokes tightly in position Remove the adjusting tools and place fully charged magnets in position and see that the armature takes either extreme position With the rotor held in position against one pair of pole faces fix the position of the rear trunnion bracket by pouring 7 anitmony lead into the holes provided 11 stop pins should now touch their respective poles faces when the armature is in either extreme position any stop pin is more than 0 002 inch away from its pole face when the opposite stop pin is seated the rear trunnion should be relocated 3623 p 16 Q UNION SWITCH amp SIGNAL REAR GASKET MAGNET REAR TRUNNION BRACKET Ai ay SEY amp n RR A LR Tee ne FS LI NP SN ASP a mm x I oO v di a lt FRONT GASKET ANTIMONY LEAD 6 I 5 u SPACER WASHERS AS REQUIRED YOKE MOUNTINC FRONT COVER SECURE COIL USING SCREWS REAR COVER A99 90 UR V COIL CONTACT FRAME TAG KP Relay Figure 3 3623 p 17 R UNION SWITCH amp SIGNAL Fasten
32. ull saturation and each magent partially demangetized by applying a convenient value of alternating flux to the magnets If a magnet is discharged too far it should again be charged to full saturation and discharged with a slightly lower value of alternating flux The magnets should be assembled on the relay with the like poles in the same direction so that with the relay in the normal operating position and with positive energy applied to the left of either coil the armature will rotate to the clockwise position as viewed from the front of the relay d In checking calibration the energizing circuit should be opened for one second before reading the pick up value and the relay should be energized to four times maximum pick up beofre reading the drop away value 4 8 2 Stick Type Relays The relay pick up reversal calibration should be checked in both directions clockwise and counterclockwise using each coil separately The pick up values must fall within the limits specified in table I If either or both are too high the magnets should be further demagnetized with a slightly higher value of alternating flux If either or both are too low the magnets must be agian fully charged and demagnetized with a slightly lower value of alternating flux For those relays which require a higher pick up in one direction than the other the fixed contact members may be adjusted slightly 4 8 3 Standard Biased Type Relays Three points are t
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