1 - Ansaldo STS
Contents
1. Washer 1 4 Stl Plate J047501 Washer 1 4 Stl Lock 1047775 Nut 1 4 20 47048002 Name Plate M451607 6601 Washer 10 Stl Lock J047733 Screw 10 32 x 5 16 J052562 Cover M451004 7101 Screw 1 4 20 x 1 2 Hex 9050012 8 A041652 Red Glyptal 040171 A1 1 1 Minibond Sub Assembly Basic N451003 1801 See Figure A 1 E 5 Coil and Core Assembly N451662 0901 10 J Bar N451004 4701 15 Mounting Plate R451004 7002 20 041844 45 Duct Sealer 041 498 50 Insert M451005 0104 55 Receptacle Connector J709146 0252 60 Screw 6 x 1 2 Rd Hd J525164 65 Terminal Pre Insul 1730039 70 Screw 1 4 x 20 x 3 J525340 1 Insulating Bushing M438881 85 Insert M451005 0105 90 Lead M438746 006 95 Wire Marker J079714 100 Bolt 3 4 x 10 3 4 Hex Hd Silicon Bronze J460119 105 Washer 3 4 Pl Flat Silicon Bronze J475196 110 Washer 3 4 Spr Lock Silicon Bronze J475197 115 Nut 3 4 10 Hex Silicon Bronze 7480304 120 Spacer 1 2 x 1 4 x 1 2 J725920 0009 125 washer 1 4 Stl Plate J047501 130 Washer 1 4 Stl Lock J047775 135 Nut 1 4 20 4048002 Encapsulated material impossible or very difficult to replace shown tor reference 6349 1 2 UNION SWITCH amp SIGNAL BEFORE ASSEMBLING LOVER APPLY REO SLYPTAL A040 EACH amp ON THE TERMINAL STRIPS ITEM JA ITEM 1220 Di 22 CONNECTOR KEY TO BE LOCATED AT THE BOTTOM AH ILLUSTRATED2. gt UNION SWITCH amp SIGNAL CAPACITOR PCB N451651 92 REV A L SZ de ee 55 Ei ER E INDICATES ELECTRIcALLY TORRET LUGS CAPACITORS ART gt _ Nee n TRACK 2 TRACK RECEIVER TRANSMITTER Figure 4 4 Capacitor PCB Tuning Current Revision Layout Also see Figure 4 5 6349 p 32 gt UNION SWITCH amp SIGNAL QJ CAE 0 0 0 0 0 A d mE TRACK 5 e 53 S Q CAPACITOR PCB RECEIVER 7 gt 2 N451657 92 nn Figure 4 5 Capacitor Tuning Earlier Revision Layout Also see Figure 4 4 Dashed line indicates electrically connected turret lugs No jumper or both jumpers are to be used for each set Do not use only one jumper in a set 6349 p 33 CLJ UNION SWITCH amp SIGNAL 6 Using temporary jumpers add or remove capacitance until a voltage peak is found for Vtc in Figure 4 4 or 4 5 the scope or digital voltmeter reading Capacitor decade boxes are recommended for this WARNING Circuit voltage may be high Use insulated tools or turn the power down 7 Adjust the source voltage to obtain the tabulated Vtc for Vtc 8 Vary the jumpers i
3. CIRCUIT 3 CIRCUIT CIRCUIT 2 gt FREQUENCY Hz Figure 3 8 Reactive Impedance Versus Frequency 6349 21 ET UNION SWITCH amp SIGNAL j BANDWIDTH BANDWIDTH BANDWIDTH PE lt e nn ii lg a maan am Figure 3 9 Impedance Versus Frequency Three Circuits in Series TRACK TERMINALS CABLE TERMINALS Figure 3 10 Circuit View From One Resonant Circuit H 4 wa UNION SWITCH amp SIGNAL gt View from Wayside Terminals Figure 3 11 shows the impedance bond reflected to the cable terminals The resonant circuits will short the coupling transformer except when one or more circuits have high impedance or when the left branch exhibits a parallel resonance with the transformer Again the design of the coupling transformer prevents it from resonating in the Frequency range of interest for AF signaling Compensation for Cable Capacitance Minibonds are tuned with a 0 1 MFD capacitor across the wayside cable terminals This is to account for the maximum capacitance expected from the 14 twisted pair cable In the field during initial track circuit adjustment a capacitor will be added in parallel with the cable as required so that the total capacitance is 0 1 MFD There will be one resonant frequency for each parallel resonant circuit No additional par
4. Sl RES EE 201 _ 25 4 3050324 amp 4 LAG GAL A 3o HHDS 35 2 Der Cam sa 14 SHES eve T asl 2 Jfojersior msur seri SB 1 26475031 caen I eal losos 11 12 WWE FOLLOWING ITEMS SUPPLIED BY IASTRULER NW CABLE 1000 TACSA 8 r c CABLE 500 MEN CABLE A WE CORON IT COPIA CONN PIN CONN TERN PAN j o WS SR o E 0 2 EL TE 1 1 221120 el EB T j 56 SILICON BRONZE 34 10 234 MEX BOLT SILICONE BRON BE Ja WSHR SILICONE BRONZE 34 10 HEX NUT SILICONE BRONZE VA LK WSHA SILICONE BRONZE 72 Y Ed AN WEW SHOWING APPLICATION WITHOUT OF 7 CABLES ANCHORED TO TIES PER INSTALLER DRAWINGS CENTER TAF CONNECTION 4 HARDWARE FOR THE MINIGOND CENTER TAP 15 SUPPLIED WITH THE MINIBOND TEMS 95 amp TOTO BE USED ONLY WHEN CENTER TAP 19 REQUIRED For 4 OR 5 CABLE CONNECTIONS SEE APPLICATION OWG D451018 54 28 FIGURE 2 5 A AWA SONO VEMOS TO BE ORDERED BY SYSTEMS ENG FER 6 0 RUQUIRENTE SEE DWG 451003 SW 33 FOR PRUT NO S A NSH
5. 1 52 REF VIEW SHOWING LOCATION OF RECEPTACLE 55 COVER BE SEALED WITH RTV 41652 ALSO SEAL 12 HOLES ON Bottow OF THE BonD 17 REF 25 9 ees 215 fee THE FOLLOWING INFORMATION SUPPLIED FOR REF ONLY T APPLICATION DWG S FOR SIMILAR MINISOND N4 51003 0 5 4 SHT S 10 11 12 amp 19 MULTI TAP T TERMINAL LUG CONNECTORS A DWG C 451004 SH 73 wWAY 4510048 7 0 2 SWAY 14 451604 7302 APPLICATION DWO 0451018 SH 2B M mATING CONNECTOR STRAIGHT AL 2 5 amp 5 PART NO 4709146 0292 B GONNECTOR TOOLS CANNON PART NOS 2 53 LER Ay 4 C HT ANGLE J S amp S ART J709146 2291 A CRIMPING M 225201 O1 2 CRIMPING LOCATOR TP 567 a ee dn REF GUIDE PINS 286 1018 000 dh REF 4 NSERTION CIT 12 N 5 REMOVAL 12 2 E m 200 MIN 300 MAX CLEARANCE WHEN CLAMPED TOGETHER 215 248210 4 REF 4 REF 0 13 SCRS REF I Ay REF 1 Figure 1 Tuned Minibond Assembly 6349 p D451003 18 Rev una UNION SWITCH amp SIGNAL DJ N451657 9202 N451657 9203 N451657 9204 N451657 9205 N451657 9101 M451662 0102 2521081 2047681 2048166 4047745 045010 0001 J7 30039 8 5 1 172 Circuit Assembly See Figure A 2 e ei N451662 1101 Used on N451003 1802 N4516
6. 2 Capacitors can be replaced Consult the parts list for capacitor information Replacement requires a tuning check and possibly an adjustment The larger the capacitor value the more likely an adjustment will be required 3 Resistor s If a resistor fails it is best to replace the whole resistor plate since the resistors are difficult to access Note the resistance values originally used or else impedance adjustments may be necessary 4 Poor connections should be cleaned and or tightened 5 Broken wires should be replaced Table 1 Component Values Bond Resonant Circuit Coil Approx Capacitance Resonant Suffix Type Leads Inductance Min Frequenc Millihenries X 10 6 Farads Hertz 0 70840 0 21095 0 15425 0 53877 0 21095 0 16936 0 35112 0 21095 0 34173 0 31979 0 21095 0 25988 29 20 5 Measured at volt 1000 Hz at 20 6349 28 UNION SWITCH amp SIGNAL gt 4 2 2 Tuning General Tuning Procedure l Each bond has three frequencies a The track transmitter frequency TT b The cab transmitter frequency CAB The track receiver frequency TR 2 Bonds are to be tuned to each of the frequencies called for in the following order lst track transmitter frequency TT varies 2nd cab frequency 4550 Hz always 3rd track receiver frequency TR varies The TT and TR frequencies are tabulated in Table 2 3 The track transmitter and the track receiver freq
7. 9 10 7 9 8 6 LONG REF 7 n f N t dae lo 9 888 REF REF tg rwn r OF RAIL AA I gre F u REY 045148603 das 406 ant Tuned MmBowlolas ase 13 T Leva TT DEC T MEMBER FRI HUMBER SHEET 0 451003 13 stl LLA L I ett bpas ooa esoderacket mountina c 35ioo4 1542 lasse mormoner se 5698 3 4 PL EK 5 6 Weur 3 4 SPRIK 58 a d ER 4 H 12 0 jeut 2 3 03 SST ANCHO d 00 5 gt 2 D 5 f NUT 4 13 HEX STL EIG Sr WSHR PL STL CAD PL WSHR Y LK STV CAD P WSHR LK SST KS e e e gt o 2 114111 5 Let 1 1 1 111 1 2 512 1 PBB s li lt 3 21 1 2 1 2 14 122 T1 TRE FOLLOWING ITEMS SUPPLIED SY IRSTALLER RET ONLY IT II IL E lese NM 011 5411 11 f lence 1 01 1 1111 I e I TT sl II 1 ll 1 1 Bol TI eem TT EII TESEO oll J TI I Li ws JI I IRAN amp BOND SE eo ee MH 0 SB SILICON BRONZE 34 104 BOLT SILICONE BROM BE 3 2 Pe WSH OA BRONZE 1 Iq DIA IONE B
8. Minibond ME run Vtc doo Pc No Er 1 5 3108 N451003 oleo Ohms Volts Ohms 0 Vtc PCB Capacitor Positions PCB Capacitor Positions Measured Cl through C8 C9 amp C10 Cll amp C12 C14 Across C15 C16 C17 8 C18 C19 C20 C21 amp C22 Table 3 Nameplate Operating Data Fred V2 2 Freq 2 15 5 05 5 15 Ohms j Hz Volts Volts Ohms Track Transmitter Volts NOTE NOTE Note When Vtc 153 volts Vz 3 00 volts When Vtc 10 0 volts Vz 090 volts Vte Voltage across resonant Values are based upon 0 amps Freq Frequency Hz cyles sec unbalance current at 6 2 Impedance magnitude 4 6vt9 DE 5 i PP a E r Ua 31 TRANSMITTER De RECEIVER UNION SWITCH amp SIGNAL AY 164 834 7 ISS A TRACK TRACK 1 7 E os D a Ra A lt F CG AF 700 Tuned Minibonds Wiring Schematic 6349 OG ee FINE TUNING JUMPERS ACTUAL USE DETERMINED DURING TUNING TESTS Figure 4 3 BOND LEADS FOUND IN CAVITY JUMPERS PROVIDED ON CIRCUIT ASSEMBLY N451622 11XX A o
9. VARIABLE 45 3P SINE WAVE IMPEDANCE MATCHING OSCILLATDR TRANSFORMER 1000 10000 Hz DIGITAL VDLT METER CAPACITOR DECADE BOX ES PLACE gt ACROSS TBD CAPACITOR gt POSITIONS PER TABLE 2 CONNECT Vie leads per table 2 Figure 4 1 Tuning Circuit Test Set Up VARIABLE POLYPROP SINE WAVE FD OSCILLATOR 1000 10000 Hz 15 FREQ COUNTER AUDIO AUDID 1662 OUTPUT 45 IMPEDANCE MATCHING TRANSFORMER Figure 4 2 Impedance Measuring Test Set Up Note Power amp output watts should exceed the combined wattage required to operate the transformer and test circuits of the bond A high impedance transformer is recommended 6349 p 27 QJ UNION SWITCH amp SIGNAL Disconnect the resonant circuit coil leads and make a continuity test across the coil leads This checks for case If the coil is not open then connect one of the coil leads and make a dc continuity test across the remaining coil lead and its connection point The test should be applied until a stable reading is obtained since circuit capacitors will draw current until they are charged If continuity exists then capacitor s is are shorted case c For the remaining cases measure the component values and compare them against what they should be as listed in Table 1 Repair of the Determined Failure 1 Coil The bond cannot be repaired unless the failure is due to a broken accessible Lead
10. SERVICE MANUAL 6349 Description Installation and Maintenance TUNED MINIBOND Part Numbers June 1985 ptw 00037 0007 UNION SWITCH amp SIGNAL 3 88 25 2776 2 S AMERICAN STANDARD PITTSBURGH 15237 COPYRIGHT 1988 USAS DIVISION OF AMERICAN STANDARD INC PRINTED IN USA 7 J UNION SWITCH amp SIGNAL REVISION INDEX Revised pages of this manual are listed below by page number and date of revision 7 UNION SWITCH amp SIGNAL gt CONTENTS Section Page GENERAL INFORMATION 1 1 1 INTRODUCTION 1 1 2 DESCRIPTION 1 1 3 SPECIPICATIONS 1 1 3 1 Electrical 1 1 3 2 Mechanical 2 A TI INSTALLATION 3 2 1 GENERAL 3 2 1 1 Track Preparations 3 2 1 2 Installation of Cables 3 25153 Cable Connections 3 2224 APPLICATION 4 III FUNCTIONAL DESCRIPTION 13 3 1 BASIC CONCEPTS 13 3 2 DESIGN CONCEPTS 16 3 2 1 General 16 3 2 2 Bond Impedance Across the Track Terminals 16 3 243 High Q Parallel Resonant Circuit 19 3 2 4 Series Connected High Q Parallel Resonant Circuit 19 3 2 5 Minibond Impedance Versus Frequency Analysis 19 3 246 Conclusions and Comments 23 IV MAINTENANCE 25 4 1 FIELD INSPECTION AND MAINTENANCE 25 4 2 SHOP MAINTENANCE 25 4 2 1 Troubleshooting 25 4 2 2 Tuning 29 4 2 3 Impedance Adjustment 34 4 2 4 Bond Assembly 36 APPENDIX A PARTS LIST D UNION SWITCH amp SIGNAL LIST OF ILLUSTRATIONS Figure Page 2 1 Floating Co
11. continuity test can also determine if the track winding is shorted if the center tap joint is insulated For cases b and the coupling transformer primary winding must be disconnected from bond leads Sl and 82 Case a can be tested by bypassing the coupling transformer If the peaks now appear then the transformer was the problem The presence of one or more peaks indicates that the problem lies in the resonant circuits The absence of a peak during a frequency sweep indicates which circuit s is are causing the problem 2 Impedance Increase Due to the nature of the design in the Tuned Minibonds an increase in impedance can occur in two ways a The Q spoiling resistor s of the resonant circuit in question has decreased in value i e shorted b Component failure of one resonant circuit shifts the tuning of that circuit to a resonant frequency near the resonant frequency of another circuit This type of failure would cause an impedance loss at the Original resonant frequency of the circuit shifted 3 Resonant Circuit Impedance Loss Some possible causes a Increase in spoiling resistor s b poor connections c shorted capacitor s d open capacitor s e shorted coil open coil g broken wire h incorrect wiring 6349 26 UNION SWITCH amp SIGNAL gt up 160 W TO BOND FREQ POWER t COUNTER AMP AUOIO AUDIO POLYPROP TO BOND FD PIN CONN p
12. impedances of each resonant circuit The reflected impedances add as in series instead of parallel because induced voltages are proportional to the change in flux through its winding The cores of all the resonant circuits pass through the track winding hence the track winding sees a total flux equal to the sum of the individual core fluxes Current passing through the track winding will cause a voltage drop across the terminals The Voltage will be transformed to the secondaries The power imparted to each secondary will be determined by the ratio of the secondary reflected impedance to the total reflected impedance The voltage impressed across each secondary will depend on a the secondary reflected impedance b the turn ratio between that secondary and the track winding When the impedances of all the resonant circuits are low the impedance across the track terminals will be low If the impedance of even one of the resonant circuits is high then the impedance across the track winding will be high An exception to this is when two or more high impedance resonant circuits develop a series resonance between them In this case the vector sum of the reflected impedances will be low 6349 p 16 UNION SWITCH amp SIGNAL 155 207 TRACK RECEIVER CIRCUIT IC 0 CONTROLLING RESISTOR 2 TURNS 121 RESISTOR REPRESENTING UE UE TRANSFORMER CORE AND WINDING RESISTANCE LOSSES 14 TWISTED PAIR CABLE TERMINALS CO
13. 25 5 N ITEM 5 TOBE ORDERED BY SYSTEMS ENGR PER REQUIREMENTS SEE DWG 451003 SV 3 FOR PRRI NOS MER RE FLONTING CONCRETE SUND A DIRECT FAX ATION TXPICAL MOUNTING L PARTS SHOWN IN FULL LINES XO BE FURNISHED BY USAS OR INSTALLER Ret Straight Plug Connector J709146 0292 Right Angle Connector J709146 0291 RE v Ui 25 SC EES PT 31210 l RES j NN gx o NOTES SCALE GIN AFT y 4 514 86 1001 TONED MINIBOND MOUNTING FART DESCRIPTION M ATERIAL SPEC IF ICATt ON DiMEHSIQNE ARE INCHES Kaf VET 22 JDUNNTER 1 1 82 eet Eent tege SS CONNECTION TO RESO SEH S AS NOTEO CON DECIMALS 2 PLACE GEN DWO NKXT ASSY TE 4 20 gt 3 PLACE EROL EC I FC NSW IGNAL DIVISION SE SE EE SWISSYALL PA 15218 N SA b E C pie ere ierch Liste oon D venners ANGULAR DUENE DEE Aur CE ERG tme 45 1486 Figure 2 1 Floating Concrete Slab REVISIONS PISS HERCLAEME CO AM F and Direct Fixation 6349 p 5 6 4 DON AM pamm g QUANTITY IDENTIFICATION 24 UI ver v 15 MNBSOND TVNED clasioo3 131 m451
14. 4 UT HEN STL BOS SL WSWR V5 PL STL CAOPL SAR V2 LK BUT VOR 2 34 WO Q3 Y4 10 WEY 55 SAR 3 4 PL FLAT SB WSR 3 4 SPRUK S ANCH BLT b 13x 3X SST 51004 BRACHEN ANGLE ATG 75121 WSHR Va LK SST ITEMS SUPPLIED BY INSTALLER CRRBLE SOO MOM LNG C NGA S AF CORDUNT CONN PAA CONN TERMINAL PIN CABLE 1000 5 21 0 Oro clays THARE RIDE E o 802 z 150 A 50119 15196 15197 20 A 5 6 45100 7812 4 A gt BBHBBDBGSEBBBBBBBBBBBBBIB SG 4 3 ER m jJ L j j j J m 2 c 2 O z gt Dn m 0 m OLW SEE VIEW SEE VIEW EJ BOO a r SA gt SILICON BRONZE 10x 234 BOLT CONE BRONZE PL WASHER GILICONE BRONZE BAO HEX NUT 7 7 CABLES ANCHORED TO NES PER SILICONE BRONZE INSTALLER DRAWINGS AN HARDWARE FOR THE MINNGOND WITHOUT CENTER TAP CONNECTION THE MINIBOND N ITEMS WO TOBE USED ONLY WHEN CENTER TAP 5 REQUIRED N ITEM 60 15 SUPPLIED WITH PLAIN WASHER amp MEX NUT STAINLESS STEEL AN FOR 4 065 CABLE CONNEC O PPPLICHTION ONG 451018 5 28 EURE
15. 5 5 ao HX gt Q LH LAN Kar 56 51 56 3 5 AION INDAS byg 4 30 1 96 5 C Bansum RNa so 3 2109 none 610970 ANDY 9 amp 7 1 OL MH el 47 9x2 AI 006 ONT 9 FIN 005 EL HS 400154 20 1 0 2 7 BOLZANNOD Ives 4 Bron S NMOMS SM CEL HS songs IDEL 7O0ISTH BALDANNDD I LW LL X08 v 1 UNION SWITCH amp SIGNAL UNION SWITCH amp SIGNAL gt 1 1 2 2 Resistor PCB N451657 9101 See Figure A 4 Terminal Strip J725715 Terminal Lug J714090 Rubber Pad M451662 0401 Resistor Plate Assembly N451662 0301 Spacer J725920 0008 Screw 8 32 x 1 Rd Hd 4052604 Washer 8 Flat J047745 Washer 8 Lock J047681 Nut 8 Hex J048166 Rubber Adhesive J041531 Wire 18 Teflon Black A045010 0001 6349 p A 13 A 14 6349 A 15 A 16 Resistor Figure 4 ee Deu m a x Cum O 5 SS x 072 Ours 8 2 81 x O 1016 1659 ESPN 824 80151538 Y 2 Z T6 LS9TSHI dede les EG 5 1691469 1 11805 8115 300727 O O O 8 1 ot 2 lt z e 9 O E z Q z 5 W
16. coupling transformer prevents such undesirable resonances from occurring The coupling transformer is designed to have a relatively large impedance and will have little effect on tuning of the resonant circuit coils Any shift that does occur is compensated for during factory test 6349 p 19 UNION SWITCH amp SIGNAL us ra ew in ern er er nar IMPEDANCE VERSUS FREQUENCY TYPICAL HIGH 0 amm gt MAGNITUDE REAL PART 4 1 OHMS FREQUENCY Hz gt BANDWIDTH 7 Z R jX X POSITIVE IS INDUCTIVE X NEGATIVE IS CAPACITIVE REACTIVE 2 M rer meer en AA EEE me Ar TES r AEE M Ue m EIER Note that 1 Z has an inductive component when f lt f 2 Z has a capacitive component when f gt f 3 Z has no reactance at f f 4 LC 9 for high 5 at resonance Z wL2 R QwL L RC 6 When parallel resonance occurs the loop current sees series resonance 7 2nf Figure 3 6 Parallel Resonant Circuit 6349 0 UNION SWITCH amp SIGNAL le BANDWIDTH Le BANDWIDTH H E FREQUENCY Hz ner mr rn rA a ur s P lir did P er v d rr i re nn Figure 3 7 Impedance Versus Frequency REACTIVE Z OHMS
17. intended only as a general guide to installation The customer should make whatever adjustments are necessary to insure a that the bonds cables and other pieces are well secured with no possibility of being damaged by low hanging vehicle rigging wheel flanges etc and b the section of track outfitted with the bonds maintains standards for tie spacing ballast support etc 2 1 1 Track Preparations Using the appropriate installation drawing for the impedance bond reposition and refashion the ties as needed to meet basic mounting requirements for the unit and any auxiliary pieces such as a protective ramp Replace any deteriorated ties which may not hold attachment screw threads reliably Where necessary excavate ballast between the ties to insure that the bond will rest flush against the ties Use the application drawing to locate hold down screw holes for the bond and other pieces with the object of installing the equipment on the center line between the rails 2 1 2 Installation of Cables Bond to bond cables are prepared according to the basic distance between bond units and special requirements such as crossbonding to other tracks Propulsion cables should be prepared with length sufficient to take up rail running motion Have the ties support the cable as much as possible and secure the cable to the tie so that only the outward end absorbs rail movements 2 1 3 Cable Connections A tin foil gasket M06961 has been used between
18. mere r 2 dH H QNS REF ul e gt 2008 5 x 22 5 gt GH ZE 90090 F451662 11 Rev 1 UNION SWITCH amp SIGNAL LO 7 72106 4792656 N451637 1101 J525093 J047765 J480006 451611 1101 4714090 J752715 0013 J752715 0012 04 3179 Cl through C30 Capacitor PCB See Figure A 3 1101 1102 1103 1104 Rd Hd on on on on N451657 9202 Used N451657 9203 Used N451657 9204 Used N451657 9205 Used Description Epoxy Sheet 1 8 Laminations Coil Screw 4 40 x 1 1 2 Washer 4 Nut 4 40 Hex End Plate Turret Lug TS1 Terminal Block 6 Way TS2 Terminal Block 4 Way Wire 18 Bare Tinned Copper For part number of capacitors see tabulation on Figure A 3 1 1 1 2 1 Item 10 15 20 25 30 35 40 45 50 55 Excluding capacitors all items are part of the basic board N451657 9201 Replacement and repair will usually require disassembly This of the complete board should 6349 p A 9 A 10 Replacement can be time consuming be considered 7 UNION SWITCH amp SIGNAL El OPERAT ING TRACK TRANSMITTER CAB TRANSMITTER CAB FREQUEHRCEES HZ SUFFIX USING FOR REFERENCE BASIC BOARD CAPACITOR 9201 A 2 CAPACETOR CAPACITOR CAPACI TOR
19. z SW IGMAL DIVISION 5 ERECTO CHE imo ormen OO 44 ANAL Di nba I m A AMERICAN STANDARD INC E ba 3 Sne EE Peron bis ka EC Qo swssvatt PA 15210 USA 2 5 ww 4 Kanon rus n or asove 2420510 3 i mmo al CT MO Inner x aur o je 61775 431486 13 en NAN Q en Figure 2 4 Vagheux Concrete Ties 6349 p 11 12 UNION SWITCH amp SIGNAL DJ SECTION III FUNCTIONAL DESCRIPTION 3 1 BASIC CONCEPTS The Tuned Minibond design and application is an extension of the basic concept described below The basic circuit configuration for an audio frequency AF minibond is represented by a primary winding with a center tap and a secondary winding inductively coupled to it see Figure 3 1 The secondary winding may be tuned to increase the impedance of the bond at desired frequencies The center tap divides the primary winding into two sections having an equal number of turns Ideally the dc resistance of each section would be the same The primary winding carries the propulsion current hence it is constructed with heavy M Figure 3 1 AF Mini Impedance Bond Basic Circuit Typically propulsion current can flow through the bond in four ways Other variations exist 1 Enters from both rails and exits at the center tap see Figure 3 2A 2 Enters from the center tap and ex
20. 0005 CAPACI C25 CAPACITOR C26 PC NO mE 4709145 0628 04067 7091 45 058 0068 J 091 45 0581 4109 45 0584 015 1J709145 0584 5 41091 45 0884 015 5 709 45 0584 J7091 45 0584 JTOI1 45 0592 J7091 45 0564 47091 45 0591 3690 4850 4109 45 0580 0047 J709146 0562 0082 709 145 0562 0082 u7091 45 0583 2890 4550 47091 45 0500 47091 45 0582 0002 109145 0382 0082 1 47091 45 0583 J703145 0581 0068 J709 45 0579 0033 709 45 008 0022 J7091 45 0576 a 4109145 0590 47091 45 058 1 J709145 058 0068 J109 45 0579 0033 01858 0022 2709145 0576 J709145 0585 022 J 09145 050 1 Cr 47091 45 0584 J7091 45 0564 o 2 gt un D lt 97 CONNECTOR TSI 152 155 8 C9 CAPACITOR PCB 4672 REY JUMPEAS TURRET LUGS ARE SHOWN FOR REFERENCE ONLY ACTUAL USE OF JUKPERS OCCURS IN THE ASS Y AS DETERMINED IN TEST SPEC 6629 T C E i K K d u ss N 45 1 h ar NEN O O 5 F451657 92 92 92 Figure A 3 Capacitor PCB 6349 A 11 A 12 12A 12B 6349 p Application of 4 or 5 Hole T Plate Connector Figure 2 5 A9N 82 8 0 ISN WOW OSL BOS DA S wo Cv 1 2 d ZESZELT ae 2 WOM OSL
21. 004 1680 BRACKET ANGALE WIG C 451004 csl i M451004 bso erRKCKET MOUNTING 451004 es a 2050060 162 Fe 1 1 s zs III Me a s 55 baue 11 EE BEER t Sa a Tes 1 45 3 4 wer sg 4 so ja s 9e 34 So 55 pjesor Sege SB II Teo Deal I 1 e es pjoersos wonn ya fe sticao e se loaves wenk vark stucmml I 55598599 FOLLOWING ITEMS SUPPLIED BY INSTALLER ARE FOR REE ONLY SEE VIEW Al el betona SEE VIEW e 96 10 MEX NUT M T Le EST SENDE SILICONE GRONBE eneue soomem 500 MCM SES M FR y TRACK amp BOND AE IO EN fence mae 10 L WEW SHOWING APPLICATION 28 mint BOND HTT T Pros Tess erste I ll ewem HT 7 6 1021 5 22202511 22242 decns rcs 0201 0153 m a Q rd m 5 8 SILICON lt 7 CABLES ANCHORED TO TIES PER INSTALLER DRAWINGS 2 un WARDWARE FOR THE MINBOND CENTER TAP VS 3 2 SUPPLIED WITH TRE MINIBOND ES WEMS 75 480 TOBE USED ONLY WHEN CENTER TAP 2 19 REQUIRED 2 1 FOR 4 OR 5 CABL
22. 62 1102 Used on N451003 1803 N451662 1103 Used on N451003 1804 N451662 1104 Used on N451003 1805 Description Capacitor PCB Used on 1101 Capacitor PCB Used on 1102 Capacitor PCB Used on 1103 Capacitor PCB Used on 1104 Resistor PCB Spacer Bracket Screw 8 32 x 7 16 Fl Hd Washer 8 Lock Nut 8 32 Hex Stl Washer 8 Flat Stl Wire Teflon 18 Terminal Pre Insul 7 UNION SWITCH amp SIGNAL NOTE ORIENTATION OF CAPACITOR PCB RESISTOR PCB PRIOR TO ASSEMBLY CRIMP TERMINALS 17 40 ON EACH END OF A I FT PIECE OF WIRE 17 45 AND INSTALL BY MATCHING TERMINALS TIR TIR RIR T E RIP ON RESISTOR PCB INSERT DGE OF EACH WHEN ROUTING WIRES FROM TERMINAL PCB TO TERMINAL STRIP ON CAPACI TO WIRES INTO RESTRAINT SLOTS ON THE PCB AS SHOWN S R COMPONENT SIDE OF RESISTOR PCB Figure A 2 Circuit Assembly 6349 p A 7 A 8 2222 rm M M de CH be n 0 det S 5 Bes E Lieu a 1 11 AM 11108 W 1 MEATH ut 2 15 1 WE Vi H 1 H I i 1 H ech ae CURA coo Wu Am JU 1 oy d I 1 11 1 pot een f MH ee in Zr 3 Hal I IL f
23. C9 CAPACITOR Cro CAPACITOR CAPACITOR C22 CAPACITOR 013 CAPACITOR C14 CAPACITOR CIS 4109145 0580 0047 J109 45 0580 7 41091 45 0580 47091 45 0588 J7T09145 057H 11093 45 0587 JTO9145 0588 H 4709145 0585 022 J709145 0586 709145 0593 33 37091 45 0593 31091 456 0593 41091 45 0593 47091 45 0593 47091 45 0570 068 J7091 45 0578 0022 J709145 0578 EA sso J709145 0591 E J709144 0576 40047 108145 0582 140082 1 J709 45 0584 015 109145 6 4103145 0593 0022 31091 45 0580 J7091 45 0578 47091 45 0588 069 709145 0578 J109145 0588 1 068 J709145 05764 0022 45 0570 47091 45 0562 1 0082 J7091 45 0584 347031 45 0593 8 45 058 4109 45 0580 4109145 0580 4108145 0582 1 0082 J709145 0584 015 J709145 0593 J709145 0580 0047 3709145 0586 058 DPERAT ENG CAB TRANSMITTER TRACK RECEIVER TR FREQUENCIES HZ FOR REFERENCE ONLY SUFFIX USING CAPACITOR CAPACITOR 7 CAPACITOR C18 CAPACITOR CAPACITOR C20 CAPAC TOR 621 CAPACITOR C22 CAPACITOR C23 CAPACITOR C24 CAPACITOR 7 CAPACITOR C28 CAPACITOR 9 CAPACITOR C30 BASIC BOARD 0068 7091 45 0579 0033 37091 45 0577 Los 37091 45 0576 4700712 ae 2590 3810 4550 0109145 00 0047 137091 45 0582 1 0082 709145 05B2 1 0082 J7091 45 0583 0005 0666 7091 45 0579 4709145 0577 1 0015 4709145 0576 4700712
24. E CONNECTIONS SEE APPLICATION Ay DWG D451018 SH 28 FIGURE 2 5 5 TO BE ORDERED BY SYSTEMS ENG X PER 6 0 REQUIREMENTS SEE DWG C451003 SW 13 a FOR PART NO S 5 RAIL CONCRETE WES TYPICAL MOUNTING A So OR 33 ANCHA SPACING SPACING T NU L PARIS SHOWN IN FULL LINES TO BE FURNISWED BY US Ek S OR NSTALLER NOTES Rel Straight Plug Connector J709146 0292 Right Angie Connector J709146 0291 MEN E SCHE GIN VET TUNED MINIBOND MOUNTING GESCAIFTION am DWWNTER 1 6 82 PARAS 1486 01 HUMBER MATERIAL SPECIFICATION MEN DIMENSIONS ARE IH INCHES N CW VK e TON TOLERANCES ON VINISIIKD W M S FINISH MAX DIMENSIONS UNLESS EXCEPT 3 AS LAYOUT OF MPEDRNCT BOND CONNECTION TO RAN OTHERWISE QKN DWG NEXT Jene eme T NOR es LESS In E CES ERT MEET CHT ors rara am D 51486 w Di Figure 2 2 Concrete Ties 6349 p 7 8 Hi LL K aSiascjatsi LAYOUT TUNED MINIBOND EET 8 IDENTIFICATION arts DEG 11 i Io LT NUMBER AX Y o o rr ge x IW i 5 lt mE SL
25. RE RAN WOOD THES TYPICAL MOUNTING L PARTS SHOWN FULL LINES TO BE FURNISHED BY VS 8 5 OR NOTES Ret Straight Plug Connector 4709 146 0292 Right Angle Connector J709146 0291 a P bh dd a hh x45148 1201 TUNED MINIBOND MOUNT SCALE IN I FT s SCALE PIMENSIONS ARE IN INCHES nr GHUI 7710 82 Tout DOCUMENT AND 18 COut wtb ARE tnt IN A PED M A ne TOUERAREKY ON FINISHED 2 97 LAYQUT OF IMPEDANCE BOND Gp INE PODA NO Arant IMEtSIONS UNLES 21 EXT PT Pie f r inn 651 2 8 srecirizo NAS woven WITH CONNECTION TO RAIL ThE 1 8 POCA siw aa BASIC DECIMALS ARTE eee SEL Ee ERR aT 2 wees 0 DIMENSI ONS GEH DWO HEXT LONHOR OF Amin ian 1 PLACE gt PLACE TO El 12 Poora EEE rta emp em oe 777 20 AMENAR SADARO IKT viri A di 7 ED MENGEI PE ESSVALE PA 15218 U PM EHACALA BY CHCI 4 81 Hare ECR ac pep re ne MATE amp dth ef 4 gt 5 SA vorm CR SHEET mene mama E on 04514 12 Wood Ties YT UNION SWITCH k SIGNAL DIVISION 1271100 OF DM Frit sat 6 6 Figure 2 3 6349
26. RONZE SILICONE ONDE CARLES ANCHORED To TIES PER VIEW B A INSTALLER DRAWINGS WER SAO APPLICA A A MARDWARE FOR TRE MINI BOND OF OUNBOND WITHOUT CENTER TAP AS SUPPLIED WIT CENTER TAP CONNECTION TUE MINI BOND ITEMS 65 amp 70 TOBE USED ONLY WHEN CENTER 15 REQUIRED A ITEM 3515 SUPPLIED WITH PLAN NS A ER amp NUT STAINLESS STEEL AX FOR 4 OR 5 CABLE CONNECTIONS SEE APPLICATION DWG 9 4 51016 SH 26 FIGURE 2 5 IAVANIBOND TEN 5 YO BE ORDERED BY SYSTEMS ENG R PER 6 0 REQUIREMENTS SEE DWG C4510093 4 18 FOR PART ZX WS RE VAGMEUR CONCRETE CES TYPICAL MTG 1 PARTS SHOWN IN FULL LINES XO BE FURNISHED BY USA 6 OR VAST ROLLER NOVES Ret Straight Plug Connector J708146 0292 Right Angle Connector J709146 028t MIN pu _ _ SCALE G IN ppp TT TT 451468 TUNED MINIBOND MOUNTING FART DESCRIPTION MATIMIALISPFECIFICATION SCALE 1 I DIMENSIONS ARE IN INCHES or KEDZIERSKI a Y EE et VEINS TE AVOUT OF MPEDANCE BOND HfAWwDARO w 0 TOLERANCES FINISHED FMS FINISH A 77 5 y SF EE a d WITH CONNECTION TO RAIL CH 7 Dh EN OR WAIVED IN z 7 DKCIMALS 2 EE NUM diia GEN DWO KEXT V STANDARD ING Ga TO Nerden br ANG ARI ATAI sols kal
27. UPLING TRANSFORMER TRACK WINDING 15 ALL RESONANT 75 102 CAB TRANSMITTER CIRCUIT CIRCUIT CDRES e E TRACK 3 1 TRANSMITTER RESISTDR REPRESENTING CIRCUIT CORE AND WINDING RESISTANT LOSSES Figure 3 4 Minibond Schematic 6349 p 17 UNION SWITCH amp SIGNAL 2 TURNS CABLE TERMINALS 311 TRANSMITTER COUPLING TRANSFORMER TRACK WINDING IS COMMON TO GE ld deed leede edel i 1 i ALL RESONANT CIRCUIT CORES TRACK TRANSMITTER u a m 4 o jh s s a opie e a caai e a t Dl old Figure 3 5 Equivalent Circuit of Figure 3 4 6349 p 18 UNION SWITCH amp SIGNAL gt 342 2 High Q Parallel Resonant Circuit The following discussion assumes knowledge of parallel resonant circuit characteristics Figure 3 6 illustrates the general characteristics of a parallel resonant circuit having a high circuit Q Figures 3 7 and 3 8 illustrate relative impedance characteristics of three high Q parallel resonant circuits having 1 different resonant frequencies and 2 non overlapping bandwidths Refer to Figure 3 7 Note that the impedance at the resonant peaks is much greater than the impedances between the peaks The impedance at a peak of one circuit is much larger than the sum of the magnitudes of the other circuit impedances Refer to F
28. ables should be inspected for possible impact damage or fraying due to corrosion and replaced if such problems are found Also tightness of various tie hold down screws should be checked to make sure the bond is held securely to the ties 4 2 SHOP MAINTENANCE 4 2 1 Troubleshooting Types of Failures 1 Loss of impedance a Component failure 1 Short 2 Open b Broken wire Bad or poor connection s 2 Impedance increase 3 Intermittent b Determining the Cause of Failure Information is provided below to assist the user in troubleshooting and repair of the bond if the user so desires However return of the bond to the factory is recommended 6349 25 D UNION SWITCH amp SIGNAL l Sweeping the Frequency to Find Peaks The best method to analyze bond failures is to test the bond in the circuits of Figure 4 1 or 4 2 A source voltage is applied and then the frequency is swept through the audio frequency range Voltage peaks across the wayside terminals or the track terminals are noted These peaks should occur at or near the tuning frequencies of the bonds There should be three peaks The absence of all peaks indicates one or more of the following a shorted coupling transformer b broken wire in the bond c loss of connection d track winding shorted e open winding in the coupling transformer incorrect wiring DC continuity tests can be used to check cases b and A
29. allel resonance will occur in the desired frequency range Factory tuning procedures compensate for the effects of one circuit upon another and for the 0 1 MFD capacitance expected in field application Factory testing procedures check each bond for proper tuning and impedance In theory resonant frequencies at the cable terminals will be the same as those at the track terminals 6349 p 23 Ce Conclusions and Comments dy UNION SWITCH amp SIGNAL CABLE TERMINALS i i I i Figure 3 11 Impedance Reflected To Cable Terminals 6349 p 24 UNION SWITCH amp SIGNAL QJ SECTION IV MAINTENANCE 4 1 FIELD INSPECTION AND MAINTENANCE WARNING TO AVOID PERSONAL INJURY WHILE MAINTAINING OR REPLACING IMPEDANCE BONDS BE SURE TO DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA No disassembly or internal repairs shall be attempted on any impedance bond if trouble is suspected defective bond unit must be returned to the manufacturer as shipped Field maintenance shall consist of periodic visual inspection of the bond for a cracked bond and bent loosened and corroded terminals Corroded terminals may be cleaned with appropriate abrasive materials and cable lugs retightened however in the event of case or terminal damage as specified above the complete bond should be returned to the manufacturer All c
30. bond is correctly tuned 6349 p 34 UNION SWITCH amp SIGNAL Table 4 Adjusting Capacitor Values Capacitor Values MFD for Board Pc No 1802 1803 1804 1805 Capacitor Circuit Positions Track Transmitter Tuning Cab C13 Transmitter C14 Tuning 005 C16 Effective C17 capacitance C18 equals 1 2 c19 the capacitor C20 values C21 Track Receiver Tuning Table 5 Capacitors Part Numbers Capacitance Commodity 00025 J709118 0005 4700712 001 709145 6 0015 J709145 0577 0022 J709145 0578 0033 709145 09 0047 J709145 0580 0068 J709145 0581 0082 J709145 0582 0100 J709145 0583 0150 J709145 0584 0220 J709145 0585 0330 J709145 0586 0470 J709145 0587 0680 J709145 0588 0820 J709145 0589 1000 J709145 0590 1500 J709145 0591 2200 J709145 0592 3300 J709145 0593 47 J709145 0597 68 7709145 08 82 J709145 0608 6349 p 35 QI UNION SWITCH amp SIGNAL 5 Reference Figure 4 2 When desired impedance Table 2 or 3 occurs VR V2 R Z Different values of VR hence Z also can be obtained by changing the jumper connections of the resistor s on printed circuit board N451657 9101 when VZ is held at the tabulated value 6 Apply tabulated frequency to the circuit of Figure 4 2 7 Apply tabulated VZ to bond terminals while holding VZ at the tabulated value Vary jumpers until desired VR is obtained see F
31. cable lugs and impedance bond terminals This gasket improves conductivity by filling imperfections in the mating surfaces The same result is achieved by tinning the terminals and lugs 6349 p 3 D UNION SWITCH amp SIGNAL a When a tinned or smooth surface lug is used with an impedance bond having tinned terminals the tin foil gasket may be omitted b tin foil gasket shall be used between the mating surfaces of an impedance bond terminal and cast cable lug or where the mating surfaces are not smooth Corrosion at the bond terminal connections can be reduced by coating the connecting surfaces with a corrosion preventive type of oil or grease A conductive type is recommended 2 2 APPLICATION 3 Figures 2 1 through 2 4 provide information for the application of the tuned minibond to 115 1b RE rail at sites employing the following floating concrete slab and direct fixation typical Figure 2 1 b concrete ties 30 or 33 spacing typical 30 shown Figure 2 2 wood ties typical mounting Figure 2 3 d Vagheux concrete ties typical mounting Figure 2 4 6349 p 4 AYOUT TUNED MINIBOND ID 451486 dE 7 Kix d 7 gt 2712 Ar 22 G 1004 a M e ENTIFICATION Iso J L ch 2 Uu YAN SO WS TUNTO gt WO OO 1 jefe le G G 5 13
32. erminals T3R T4 Ohms Resistors Cab Transmitter Terminals T2 Ohms Resistors Track Receiver Terminals R R R2 Ohms Resistors 0 0 Short TR Short CAB 0 0 Short TT 25 25 1 0 1 0 450 50 1 5 1 51 75 1 25 amp 50 2 0 2 0 1 00 75 amp 25 Short 5 2 5 1 0 amp 1 5L gt 1425 715 845 3 0 1 5L amp 1 58 75 amp 5 8 25 Short 5 1 0 3 5 2 0 Short 1 0 1 51 5 amp 1 0 1 04 BOG 145b 1 58 4 5 2 0 amp 1 08 1 51 5 0 2 0 Short 1 0 1455 L 5R 6 0 2 0 amp 1 0 amp 1 51 amp 1 5R 6349 p 37 SERVICE MANUAL 9 Appendix A PARTS LIST TUNED MINIBOND Part Numbers 451003 1802 1803 1804 1805 June 1985 D0037F DN0007F UNION SWITCH amp SIGNAL AMERICAN STANDARD INC PITTSBURGH 15237 3 88 25 2776 2 COPYRIGHT 1988 US amp S DIVISION OF AMERICAN STANDARD INC PRINTED IN USA UNION SWITCH amp SIGNAL gt APPENDIX A PARTS LIST TUNED MINIBOND Complete See Figure 1 1 Cab 4550 TT 2590 TR 3870 N451003 1802 Cab 4550 TT 2970 TR 3690 N451003 1803 Cab 4550 TT 3690 TR 2590 N451003 1804 Cab 4550 TT 3870 TR 2970 N451003 1805 N451003 1801 N451662 1101 N451662 1102 N451662 1103 N451662 1104 Minibond Sub Assembly Basic Circuit Assembly Used on 1802 Circuit Assembly Used on 1803 Circuit Assembly Used on 1804 Circuit Assembly Used on 1805
33. hen filled with an epoxy compound and cured The mold forms a cavity at the back of the bond There are four long studs inside the cavity These studs are used to mount a circuit assembly Each circuit assembly contains two boards One board contains a coupling transformer and capacitors for tuning the bonds The other board contains the resistors used to adjust the impedance of the bonds A sealing compound is applied to the back edges of the bond where the cover is assembled The cover will make contact with a steel plate on the resistor printed circuit board This provides a heat sink path for resistors located on the reverse side of the plate A two pin connector protrudes from one side of the bond This is where the connection to the wayside equipment is made A nameplate is located on the opposite side Six 1 2 13 by 1 3 8 approx inch studs protrude from the bottom of the bond These studs are welded to the mounting plate mentioned earlier These studs are used for mounting the bond during installation 6349 p 2 UNION SWITCH amp SIGNAL SECTION II INSTALLATION 2 1 GENERAL WARNING TO AVOID PERSONAL INJURY WHILE INSTALLING IMPEDANCE BONDS BE SURE TO DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA NOTE Installation requirements for an impedance bond are controlled primarily by the physical specifications of the user s trackage and associated signal hardware The following remarks and drawings are
34. igure 3 8 Note that between the resonant peaks some curves are positive and some are negative If these impedances were connected in series they would tend to offset each other 3 2 4 Series Connected High Q Parallel Resonant Circuits Figure 3 9 illustrates the magnitude of the impedance for the three parallel resonant circuits of Figures 3 7 and 3 8 connected in series Note that this curve appears similar to Figure 3 7 It is possible that the impedance peaks will occur at frequency values slightly different than those in Figure 3 7 Between resonant peaks the parallel resonant circuit contributes reactive impedance of opposite sign At particular frequencies series resonance will occur Such resonance will occur once between 3 2 5 Minibond Impedance Versus Frequency Analysis View from Track Terminals Refer to Figure 3 5 The coupling transformer is connected in parallel to the series network of parallel resonant circuits Signals from and to the wayside cable are coupled through this transformer If this transformer impedance was sufficiently low the impedance across the track terminals would also be low Figure 3 10 shows the circuit viewed from one resonant circuit Note that if a series resonance occured in the right circuit branch a low impedance would also be produced across the track terminals A series resonance occurring near one of the parallel resonant frequencies is not acceptable The design of the
35. iqure 4 3 and Table 6 per Table 2 or 3 Measure and record the values of 2 and VR Calculate the impedance of the bond Impedance V2 R VR 8 Replace temporary jumpers with 18 buss wire and solder the buss wire to the turret lugs Exception Use insulated wire for connections to T3R and T4 9 Repeat steps 3 through 8 for the remaining frequencies Cab Transmitter and Track Receiver NOTES a resistor decade box may be used to determine the amount of resistance required The closest available resistor selection is then chosen 5 amp rating is recommended for the decade box b An increase in value of the adjusting resistor will decrease the impedance of the bond 4 2 4 Bond Assembly a Final Assembly 1 Apply Red Glyptal A040171 to a corner of each terminal strip screw 2 Assemble printed circuit board assembly into the bond Apply Red Glyptal 4040171 to the nuts 3 Clean edges of the bond cavity with a clean cloth Apply RTV to the bond cavity edges and assemble covers 4 Check impedances at the operating frequencies per Table 3 and Section 4 2 3 Step 7 NOTE The purpose of the Red Glyptal is to prevent loosening of the serews and nuts due to vibration Any non corrosive non conducting material that will perform this function may be used 6349 p 36 UNION SWITCH amp SIGNAL gt Table 6 Impedance Adjusting Resistor Selections Track Transmitter T
36. its at both rails see Figure 3 2B 3 Enters at one rail and exits at the other rail Usually the center tap would not be used see Figure 3 2C 4 Enters at one rail and exits at the center tap or vice versa see Figure 3 2D 6349 p 13 CURRENT TRANSFORMED SIGNAL VOLTABE CURRENT CURRENT TRANSFORMED AC SIGNAL VOLTAGE TOTAL M PROPULSION CURRENT 81 8020 CURRENT CURRENT CURRENT TRANSFORMED SIGNAL VOLTAGE 9941 831433 CURRENT app 0 CURRENT CURRENT TRANSFORMED AG SIGNAL VOLTAGE Y3LN3 CURRENT Flow EH Figure 3 2 Typical Propulsion Current UNION SWITCH amp SIGNAL TOTAL PROPULSION Vac CURRENT SIGNAL CURRENT DC CURRENT RAIL 2 SE Figure 3 2A RAIL 1 CURRENT W EB e e AC SIGNAL CURRENT Vat DC CURRENT ES RAIL 2 Figure 3 2B RAIL gt 0 DC CURRENT BALANCING CURRENT TOTAL PROPULSION Vac CURRENT SIGNAL CURRENT RAIL 2 Figure 3 2C SIGNAL CURRENT TOTAL PROPULSION CURRENT 1 Vac RAIL 2 Figure 3 2D 6349 p 14 UNION SWITCH amp SIGNAL gt For cases 1 and 2 the total dc propulsion current flow is divided between the two halves of the primary winding The current direction in one half will be opposite the current direction of the o
37. ncrease or decrease capacitor decade box value until a voltage peak is found WARNING Circuit voltage may be high Use insulated tools or turn the power down 9 Turn the power down Jumper capacitors into the circuit which approximate the value of the decade box Tables 4 and 5 are provided as guides Exception for the cab transmitter frequency two capacitors in series are required The capacitor values will be twice the value of the decade box Two jumper connections may be required to place PCB adjusting capacitors into the circuit The effective capacitance equals one half of the value of one capacitor The number of jumpers required depends upon which PCB revision the minibond is equipped with 10 Repeat steps 6 through 8 until the voltage peak occurs at the tabulated Vtc 11 With Vtc set to the tabulated value vary the frequency until a voltage peak is obtained This frequency shall be within the tabulated tolerance of Table 2 12 Solder the appropriate capacitors into the circuit using 18 buss wire to make permanent jumper connections Excess length is to be trimmed After cooling clean flux residue from the solder connections 4 2 3 Impedance Adjustment a Adjusting Impedance 1 Assemble the circuit of Figure 4 2 2 Measure and record the resistance of the 4 ohm approx resistor R of Figure 4 2 3 Apply the track transmitter frequency to the circuit Set Vtc to the value tabulated in Table 2 4 Verify
38. ncrete Slab and Direct Fixation 5 6 2 2 Concrete Ties 7 8 2 3 Wood Ties 9 10 2 4 Vagheux Concrete Ties 11 12 2 5 Application of 4 or 5 Hole T Plate Connector 12A 1 2B 3 1 AF Mini Impedance Bond Basic Circuit 13 3 2 Typical Propulsion Current Flow 14 3 3 AF Mini Impedance Bond Circuit Application 15 3 4 Minibond Schematic 17 3 5 Equivalent Circuit of Figure 3 4 18 3 6 Parallel Resonant Circuit 20 3 7 Impedance Versus Frequency 21 3 8 Reactive Impedance Versus Frequency 2 3 9 Impedance Versus Frequency Three Circuits in Series 22 3 10 Circuit View From One Resonant Circuit 22 3 11 Impedance Reflected To Cable Terminals 24 4 1 Tuning Circuit Test Set Up 27 4 2 Impedance Measuring Test Set Up 27 4 3 AF 700 Tuned Minibonds Wiring Schematic 31 4 4 Capacitor PCB Tuning 32 4 5 Capacitor Tuning 33 LIST OF TABLES Table 1 Component Values 28 Table 2 Tuning Data 30 Table 3 Nameplate Operating Data 30 Table 4 Adjusting Capacitor Values 35 Table 5 Capacitors Part Numbers 35 Table 6 Impedance Adjusting Resistor Selections 37 11 UNION SWITCH amp SIGNAL gt SECTION I GENERAL INFORMATION 1 1 INTRODUCTION The Tuned Minibond is an extension of the basic audio frequency AF minibond with a center tapped primary and an inductively coupled secondary winding that is tuned to increase the impedance of the bond at desired frequencies 1 2 DESCRIPTION Like the basic AF Minibonds the Tuned Mi
39. nibonds have a center tapped propulsion winding and permit coupling of ac siqnals between the secondary winding and the propulsion winding The Tuned Minibond differs in the number of cores and secondary windings The Tuned Minibond has three magnetic cores Each core has two secondary windings The propulsion winding is common to all three cores see Figure 3 4 The high turn secondary winding of each core is tuned to a particular frequency depends on the part number of the bond The low turn secondary windings are series connected The group is connected to the high side of a coupling transformer The wayside equipment would be connected to the low side of the transformer The use of two secondaries per core allows the tuned windings to be isolated from each other Since each parallel resonant circuit has its own magnetic core the bond impedance can be represented as the sum of the reflected impedances of the resonant circuits This is true for both the propulsion winding termination and the wayside termination The impedances can be complex Section 3 2 Design Concepts discusses the above in more detail Fach circuit is tuned to a different frequency called the resonant frequency At the resonant frequency the impedance of the resonant circuit is high The reflected impedance to the track or wayside will also be high In summary the bond s reflected impedance to the track or wayside terminals will be high near any one of the three resona
40. nt frequencies Away from the resonant frequencies the bond impedance will be low 1 3 SPECIFICATIONS 1 3 1 Electrical All Tuned Minibonds Style AF Mini Type DC Propulsion DC Resistance 0 00003 10 ohms rail to rail at 20 C Current Unbalance 250 amps dc through one turn of the propulsion winding based on the operating characteristics of the AF 700 track circuit system DC Propulsion current 3000 amps dc per rail continuous 6349 p l gt UNION SWITCH amp SIGNAL b Impedance and Resonant Frequencies Part No Track Trans Track Rec Suffix 2 10 Freq 5 2 10 Freq 5 2 10 Freq 5 1802 3870 1803 3690 1804 2590 1805 2970 Some bonds are off tuned at given frequencies to increase their dc unbalance current capacity Values are based upon zero amps of dc unbalance current at 20 C and at specified voltage levels Impedance values will vary with variations of these parameters 1 3 2 Mechanical The Tuned Minibond utilizes moly permalloy toroidal cores to construct three coils Each coil has two windings The three coils are bound together to form a coil assembly The low turn windings of the coils are series connected Two J shaped of 1 1 4 inch copper are passed through the window of the coil assembly to form the two turn track winding The coil and core assembly mounting plate receptacle box connector inserts and screws are assembled into a mold The mold is t
41. ther half The magnetic fluxes induced the magnetic core of the bond will each other and thus will tend to cancel each other Equal currents balanced will cancel completely An excessively large current unbalance will cause a loss in the ac signaling impedance The signaling current ac enters through one rail and exits through the other rail It traverses the whole winding in one direction hence no ac flux cancellation occurs An ac Signal is induced into the secondary winding Similarly an ac signal can enter the secondary winding and induce a signal into the primary coil For case 3 the bond allows the propulsion currents to be re distributed In general this tends to equalize the current in the rails In this application the bond does not benefit from cancellation of the dc current induced magnetic fluxes hence the dc unbalance current capacity is reduced The unbalance capacity becomes half of the established rating since current flows through both halves of the propulsion winding In addition the current capacity of the bond is also one half of the established unbalance capacity Case 4 is similar to 3 except that the current flows through one turn instead of two The bond will handle the established unbalance current rating A typical application of an audio frequency style minibond system is shown in Figure 3 3 The center tap on each bond is shown unconnected however in certain applications the tap may be
42. uencies are generally not tuned to the frequencies listed in the bond tabulation operating frequencies Bond tuning will use the frequencies tabulated in Table 2 tuning frequencies 4 Bonds are tuned by adding small values of capacitance These capacitors are located on printed circuit board N451657 92XX They are added to the circuit by soldering 18 buss wire to the appropriate turret lugs see Figure 4 3 wiring schematic 5 Bonds are adjusted for impedance in a similar fashion This adjustment is made on printed circuit board N451657 91XX per Section 4 2 3 after the bond is tuned 6 Both printed circuit boards are assembled into an assembly 451662 11 Specific Tuning Procedure 1 Read Section 4 2 2A General Tuning Procedure before tuning bonds 2 Assemble circuit of Figure 4 1 3 Adjust the frequency generator to the desired frequency 4 Connect temporary jumpers to the resistor terminals see Figure 4 3 RIR and R2 0 25 ohms TIR and T2 1 5 ohms T3R and T4 2 0 ohms However if permanent jumpers are already in place these may be tried first 5 Adjust the source voltage to obtain 1 2 the tabulated Vtc Vtc Table 2 for the frequency concerned 6349 p 29 HOLIMS NOINN CP Vte 3 E Volta Volts 0 1600 0 1905 0 2667 0 2323 Capacitor Positions 23 through C30 Table 2 Tuning Data Track Transmitter Tuning Cab Transmitter Tuning Track Receiver Tuning
43. used for connections to other bonds on the same or adjacent tracks TO TO TRANSMITTING RECEIVING EQUIPMENT EQUIPMENT Figure 3 3 AF Mini Impedance Bond Circuit Application 6349 p 15 D UNION SWITCH amp SIGNAL 3 2 DESIGN CONCEPTS 3 241 General Figure 3 4 shows a general schematic of minibonds N451003 1802 through 1805 These bonds are tuned to three frequencies cab transmitter track transmitter and track receiver The track winding is common to all the toroids The high turn winding of each toroid is the inductor of a parallel resonant circuit Each parallel resonant circuit inductor has a core that is independent of the other resonant circuits Figure 3 5 shows an equivalent circuit of Figure 3 4 The resonant circuits have been reflected to the low winding side of the toroidal coils 3 2 2 Bond Impedance Across the Track Terminals The inductance of the track winding is around one micro henry The reactance across the track terminals will be very low in the audio frequency range A value of 0 03 ohms would be typical at 5000 Hz The impedance can be increased by tuning the winding Tuning a secondary winding instead of the track winding allows use of smaller capacitors High impedances require high circuit Q s and will only occur near the resonant frequency The minibonds have three parallel resonant circuits connected in series The impedance across the track terminals will be the vector sum of the reflected
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