3 - Ansaldo STS
Contents
1. 4 3 2 Test Procedure NCTE This procedure makes reference to two different versions of the reset module internal PC3 Rev 1 or Rev 2 and above Rev 2 Make note of the revision number the board before conducting these tests Verification er rd Operation 1 Connect the reset module into the test circuit as shown in Figure 4 1 Notes Make sure the reset module and the code relay are in the upright position Decade resistors R1 and R2 only apply to Rev 2 Note Steps 1A through 1K are for the Rev 2 only 1A Set the MODE switch to steady IB Adjust the amplifier so that V1 reads 0 00 Vac RMS 1c Set oscillator no 1 to 100 Hz and oscillator no 2 to 7 Hz 420 code 1D Set decade resistor R1 to 510 ohms and decade resistor R2 to 100 onms lE Adjust the amplifier output so that multimeter Vl reads 8 4V ac RMS Adjust decade resistor R2 to a value that allows the internal power relay to pick up at the 8 4 ac input level The test licht should turn off 1G Remove the R2 decade box and solde equivalent 1 29 555 carbon zasistor in its place Note I2 the 8 4V ac pick up cannot be achieved ac R2 0 9 ohms replace X on the PCS 1H lJ 10 Set oscillator no M en Operation Adjust the amplifier output so that 1H multimeter Vl reads 5 9V ac Adjust decade re2. UNION SWITCH amp SIGNAL A mambar of the ANSALCO Group 5800 Corporate Drive Pittsburgh 15237 SERVICE MANUAL 6237A Installation Operation Field and Shop Maintenance DE Dual Frequency Code Reset Module N451206 0301 August 1993 A 3 92 3012 P amp C MAC i 6237A CCPYRIGHT 993 UNION SWITCH 4 SIGNAL PRINTED iN USA am t REVISION INDEX Revised pages of this manual are listed Sy page number and date of revision Sar Phe e CO m 1 H i i q 1 B Ur GR WN i gt H H pa N C HH bi NPH H A A A pp DD Pp INSTALLATION EQUIPMENT RACK MOUNTING SHELF MOUNTING FUNCTIONAL DESCRIPTICN GENERAL DETAILED MAINTENANCE AND TEST PROCEDURES GENERAL FIELD CHECKS Recommended Test Equicment Procedure OPERATIONAL SHOP TESTS Recommended Test Equipment and Set Up Test Procedure COMPONENT SHOP TESTS General Series Tuned Circuits Test 1 Recommended Test Equipment and Set Up 2 Test Procedure Transformer Test Recommended Test Equipment and Set Up 1 2 Test Procedure PARTS LIST COMPLETE ASSEMBLY N452296 0301 RESET PCB N451807 7601 ILLUSTRATIONS Installation Diagram System Application Diagram Reset Mcdule Schematic Diagram Operational Shop Test Ser Ur Series Tuned Circuit Test Set Up Series
3. aut mar al BP ambe enam r pu s m o Ll D 2 PLACES SE VESES 2 PLACES 111117777755 32414144445 P Li AP We 5 Unit Compiet2 Assembiv do o Ro gt Da tty SECTION A A Figure Sanit Completa Assembly Cont d _ITEM C Ce Kl 06 09 TL1 6 Rl R2 R6 R1 R2 R3 R4 R5 D1 D5 RESET PC3 451807 7601 See Figure 2 Capacitor 47 29 de Capacitor 4700 mFd 16 Relay 12V dc SPDT Diode 1N4005 600V Turret Lug Resistor TBD Resistor 300 Ohm 1 2 W Resistor 680 Ohm 1 2 W Thermistor 100 Chm Resistor TBD Transformer Diode Tie Cable Clamp _ 0585 PART NO J706254 J720773 J720759 J731405 0021 J731400 0054 17721251 2726150 0274 3703372 0003 a Y Lu OO cu EU v 911 911 SOE USA MADE IN Tomponent 7 La YCcut 5 Rese 2
4. Tuned Test Oscilloscope Waveform Trans e aer Test Set Up Transformer Test Oscilloscope Waveform 3 Unit Cemplete Assembly Reset 2C3 Component Layout NON 1 F RP qa C3 l C3 ps pP bf p P Io oi P l E l d 4 N RR l 4 d l F r 13 00 OY gt l H 1 A 4 pu 4 AD ty Eod E Ww SECTION I GENERAL INFORMATION 1 1 INTRODUCTION This manual describes the operation installation and maintenence of the Dual Frequency TRU II Code Reset Module US amp S part no N4512C6 0301 The module is designed for use with a TRU II Track Rescnant Unit refer to service manual SM 6236 when the latter is applied in code overlay applications When a track circuit shunt is released in a TRU II code overlay arrangement the mcdule provides the release of the V frequency contzol relay allowing the TRU II to reset with steady energy track feed The module is a plug in package designed for mounting on a standard relay rack configuration using a special mounting plate The Dual Frequency TRU II Code Reset Module differs from the earlier Code Reset Module part number N451206 02XX in the following respecrs A Operates at a second carrier frequency of 250 Hz B Provides reset capability for additional standard code rates of 270 and 420 C Does not function as a vital device
5. external connections Make certain curing reassembly that all parts and wiring connections are returned to their correct locations NCTE operational shop tests described i the unit is returned to service When reassembly is complete the unit must be given the n section 4 3 beicre 4 4 2 Series Tuned Circuits Test 4 4 2 1 Recommended Test Equipment and Set Up Device Digital Multimeter qty 1 Fluke 8000A Oscillator qty 1 Wavetek Model 200AB Amplifier qty 1 Macintosh Model 2100 Frequency Counter qry 1 Hewlett Packard 5307A Counter Oscilloscope qty 1 2 channel Tektronix 434 DC Ohmmeter qty 1 Decade Resistor Box qty i 3 Corneil Dublier See Figure 4 2 for the set up of this test ecuipment to ME 9 la Q1 OSCILLATOR T COUNTER FREQ OSCILLOSCOPE AMPLIFIER GND CHANNEL CHANNEL 4 4 2 2 Test Procedure Overation uns i Verification 2 1 Measure the inductor s dc resistance value and compare it to the value listed in Table 4 1 2 To perform an operational test a 2 tuned circuit inductor capacitor combination electrically isclate the circuit by disconnecting the lead wire on bopbin tab A and connecting the tuned circuit into the test circuit shown in Figure 4 2 3 With oscilloscope inputs set for dc 3 input signals adjust the vertical traces so that their ground levels are on the middle horizontal l
6. reset is accompiished by the reset module which after several 100 Hz or 91 67 Hz code cycles picks up the RRP relay The v relay stick circuit is released and the source is switched back to steady energy permitting the TRU i to pick up NOTE The Dual Frequency TRU II Code Reset Module is not con Sidered vital since resetting code to steady energy is not a vital function The TRU II Track Resonant Unit provides the required steady energy pick up 3 2 DETAILED See Figure 3 2 The Dual Frequency TRU II Code Reset Module accepts 91 67 and 100 Hz input signals from the W 400 track transformer at pins 6 and 7 The nominal input signal level is about 10V ac RMS A series tuned filter consisting of C4 and L23 is connected in series with the input to transformer 2 A second series tuned circuit consisting of C3 and Ll is connected to the secondary of transformer T2 in series with the PC board lead Under minimum input signal of 9V ac RMS transformer T2 operates as a normal transformer device When the input increases above this minimum level T2 begins to saturate thus limiting the amplitude of the signal The C3 Li filter tunes out the harmonics created by the saturable transformer action In addition to providing amplitude limiting for in band signals 91 67 and 100 HER T2 also provides amplitude limiting for 25 Hz 60 Hz propulsion zen es The amplitude limiting level at 00 Hz is about 60 of the 100 Hz limiting level
7. suspected of being defective should be replaced with one known to be in working order If a module is found to be defective it should be given the shcp troubleshooting and repair procedures section 4 3 or returned to US amp S for or replacement Call 1 800 652 7276 for factory service information atzempt should be to repair the module in the field WARNING EXTREME CARE SHOULD BE EXERCISED DURING POWER ON TESTS OF TEE DUAL FREQUENCY TRU II CODE RESET MODULE CONTACT WITH TERMINALS MAY RESULT IN PERSONAL INJURY 4 2 FIELD CHECKS Since the reset module is always used with TRU II code overlay applications its operation can be verified as part of the TRU II system field check 4 2 1 Recommended Test Equipment Device Multimeter qty 1 20 000 ohm volt e g Simpson 260 or equivalent 4 2 2 Procedure Check that the reset module and associated equipment are properly installed including condition and tightness of all terminal connections 2 Measure voltage across reset module input socket terminals l 2 Voltage should always be steady energy in 110 to 120V ac RMS 3 test the reset module itself shunt its associated track circuit At this time the track feed should shift from steady energy to a coded energy mode Cn release of the shunt track relav should energize a ter 5 to 10 second delav 4 3 OPERATIONAL SHOP TESTS
8. while the limiting level 25 Hz is about 25 o the 100 Hz inicias E The 250 Hz signal frequency is also limited the combination filters and saturable transformer The series tuned circuits are stagger tuned to provide a wide bandwidth for dual Tremiency and high code rate operation or 42 UY t ddl OL FINGON 13534 ZH 001 X8 AAA I f 1 vol 1 1 SIDVINOD SM t gt a 1 gt lt gt ca ZH QSC The fiiters transformer combination cutput signal is connected to terminals 1 and 2 of the PC board where it is full wave rectified via diodes 01 02 D3 and 04 DC output pulses charge capacitor C2 4 700 uF through steering diode DS Resistor R4 27K provides a high impedance discharge path for C2 The output of che full wave rectifier also charge capacitor Cl 47 uf via the back contact of mercury wetted reed relay Capacitor Cl has series conneczed 685 chm relay coil resistor R2 and parallel combination o RS ard R6 as a fixed relatively fast discharge path When 1 67 or 100 Hz code pulses are applied several seconds are required before relay XZ can pick up due to the charge time of capacitor C2 When Kl picks up Cl provides the relay coil feed over the ccntact transfer time When the K1 front co
9. NOTE The shop tests given in this section must be performed on all Dual Frequency TRU IZ Code Reset Modules suspected of haviag an internal fault before these units can be returned to service 4 3 1 Recommended Test Equipment and Ser Up Revice Specificatii Oscillator 1 Waverek Model 146 Oscillator qty 1 Wavetek Model 115 Amplifier qty 1 Macintosh Model 2100 Frequency Meter qty 1 Hewlett Packard 5300 Measuring System zequency Counter 1 Hewlett Packard 5307 Counter Digital Multimeter qty 1 Fluke 8000A Track Transformer qty 1 US amp S W 400 parc no N451428 0104 Reed Relay qty 1 24 volt Clare HGOM51i11TCO or US amp S part no J726153 0067 Diodes qty 2 1N4C04 Toggle Switch qty 1 S P oS Resistor aty 1 1K chm 25 wats Decade Resistor Boxes qty 2 3 Cornell Dublier Control Transformer qty 1 24 volt Light Bulb with Base qty 1 24 volt Breakdown Voltage Tester Higkpor Junior See Figure 4 1 for zhe set up of this cast equipment equivalent METER MULTIMETER dip ab A on a 22 STEADY CODE SWITCH DECADE 25W RESISTOR R1 gr TRANSFORMER 24V TEST E RESET VIODULE DECADE RESISTOR Ww gt ut Sm _ POWER A ae ae l anana 7 4 1 5noo 28537
10. ine 4 Adjust the input signal channel L 4 scope to about 6 0V 5 Adjust the frequency to the value 5 wi shown in Table 4 1 6 Adjust the input signal so that 6 multimeter VR reads 1 00V ac RMS During the tuning period maintain this 1 00V ac RMS level 7 Adjust the oscillator frequency so T that the oscilloscope traces appear as shown in Figure 4 3 Note If an inductor or capacitor is found to be defective born must be replaced because they are assembled and tested a matched pair Table 4 1 Series Tuned Circuit Test Values Filtex Coil d Tuning Point N451039 Resistance LC Network Signal Levels Ohms Hz Va Scope CH 2 Min Max Min Max Volts AC RMS Cutput 2 20 WHEN NETWORK IS PROPERLY TUNED BOTH TRACES CROSS AT THE SAME POINTS 4 4 3 Transformer Test 4 4 3 1 Recommended Test Equipment anc Set Us Device Oscillator aty 1 Wavetek Model 146 Frequency Counter qty 1 Hewiett Packard 5307A Counter Amplifier qty E 1 Macintosh Model 2100 Decade Resistor Boxes qty 2 3 Cornell Dublier Oscilloscope qty 1 2 channel Tektronix 453 Digital Multimeter qty 1 Fluke 8000A See Figure 4 4 for the set up of this test equipmenc Or equivalent 900 OHM 8 OHM OSCILLATOR AMPLIFIER 4 4 3 2 Test Procedure Measure the transformer primary anc Operation dr secondary c
11. ntact is made the relay feed circuit has steering diode 07 and an additional resistor R1 connected in series with its coil This action increases the reset module s input impedance to about 1K ohm The Ki relay remains energized since the release voltage level is considerably below the pick up voltage Relay K2 is a power relay repeater cf It is powered by the local 115V 91 67 or 100 Hz input to PC board terminals 5 and 6 Transformer Tl in conjunction with diodes D8 and D9 maxe up and unfiltered 12v dc power source for the relay Resistor R3 is a 680 ohm device The output from this dc supply is fed through the front contact of Kl to the K2 repeater relay Diode D6 is a relay coil snub PC board resistors Rl and R2 are shown as TED to be determined for adjustment purposes due to variations in manufacturing specifications for Thermistor R5 and parallel resistor R6 are for relay temperature compensation P C BOARD D8 7 115 Th I ATL6 YTL5 e SUPPLIED i WITH LI 125 20 PVC UNLESS OTHERWISE SPECIFIED ALL WIRE 6 SUPPLIED WITH 12 PLUG WHT 814 PVC WHT 14 NOTE BALLOCN CALL OUTS REFER TO PARTS LIST SECTION A 1 Figure 3 2 Reset Module Schematic Diagram SECTION IV MAINTENANCE AND TEST PRCCEDURES 4 1 GENERAL Initial checks of the Dual Frequency TRU II Code Reset Module consist of observing the track relay pick up during code reset A module
12. oil resistances To perform an operational test on 2 transformer T2 electrically isolate it by disconnecting the Orange wires to PCB turret lug no 1 The connect the transformer to the test circuit shown in Figure 4 4 Adjust the frecuency to 100 Hz 3 Adjust the amplifier output level 4 so that multimeter Vl reads 9 00V ac RMS 10 mA input current Adjust oscilloscope channel 1 to 10 5 volts cm and channel 2 to 5 volts cm Set the time div to 1 0 msec per division 1 MSEC CHANNEL 2 VP Verificacion Resistances should read within range of 2 47 to 2 70 ohms Channel 1 should read 49 to 51 volts P P Channel 2 should read 24 5 to 25 5 volts P P Channel 2 waveform should lead channel 1 waveform by 0 2 to 0 3 msec as shown in Fiaure 4 5 LAG CHANNEL 1 Figure 4 5 Transformer Test Oscilloscope Waveform UNION SWITCH amp SIGNAL Sl SERVICE MANUAL 5237A APPENDIX A PARTS LIST Dual F requency TRU II Code Reset Module August 1993 4 92 3012 MAC 6237 COPYRIGHT 1992 UNION SWITCH amp SIGNAL NC PRINTED IN USA E 1 COMPL Nut ASSEMBLY N451206 0301 See Figure A 1 _ DESCRIPTION Cover Body Mounting Plate Body 2lug Namepiate Screw 2 x 1 4 Round Head Screw 38 32 x 3 8 Pan Washer 8 Lock Nut 8 32 Reactor Reactor Transformer Reset Prin
13. older track lines 10V ac to secket terminals 5 and 6 on the module 4 Solder external signal wires for relay control to socket terminals 3 and 4 on the module 2 2 SHELF MOUNTING When shelf mounting the TRU II system instali a mini rack with the required combination of track resonant unit reset module track relay and repeater relav This rack has a resistor unit terminal block mounted in place next to the terminal strips DUAL FREQUENCY TRU II CODE RESET MODULE REAR VIEW NOT TO SCALE _ LOCAL SIGNAL V RELAY 110 120V CONTROL o TRACK 10V 7 5 16 NOT USED VIA RACK CONNECTOR SECTION III FUNCTIONAL DESCRIPTION See Figure 3 1 3 1 GENERAL See Figure 3 1 ee TRU II Code Reset Module is designed to take its signal input zom the tracks in parallel with the TRU Ii Track Resonant Unit The local input is only used for internal power Track relay no 1 back contact is connected in series with the reset module input in order to disconnect the source during steady energy track conditions When a train shunts the normally steady energy track circuit the no 2 track relay back contact connects the 812 source to the relay by way of the RRP back contact and traffic control circuits The V relay connects the source 100 Hz and 250 Hz coded energy to the track input When the train vacates the track circuit the track system must be reset to the steady energy mode The
14. refer to section 3 1 D Replaces all 02XX models wich a single unit 1 2 SPECIFICATIONS Dimensions H 8 W 2 3 8 D 9 1 2 Weight 5 lbs Mounting Standard relay rack Local Voltage 110 or 120V ac 103 8 50 60 91 67 or 100 Hz Local Current 20 ma Track Voltage 10 0 to 30 0V 10 2 91 67 and 100 Hz Track Current 9 mA Q 9V energized state Dielectric Breakdown Voltage 3 907 ac RMS 60 Hz for one All terminals to chassis Propulsion Power DC 22 60 Hz Frequency Immunity Reset will not energize 25 Hz propulsion 1507 29512 25072 250 signal 1257 ac nm s A uc a Maximum Code Rate 420 code Minimum Coder On and 383 Off Time Operating Temperature Range 40 C to 70 C 4 x asia 12 een SECTICN II INSTALLATION See Figure 2 1 WARNING CERTAIN SIGNAL AND OPERATING POWER TO THE DUAL FREQUENCY TRU II CODE RESET MODULE REMAINS OFF UNTIL ALL INSTALLATION PROCEDURES ARE COMPLETE OTHERWISE PERSONAL INJURY MAY RESULT 2 1 EQUIPMENT RACK MOUNTING NOTES The Dual Frequency TRU II Code Reset Module is available with rack mounting plate included refer to Appendix A The TRU II Track Resonant Unit and reset module must be mounted side by side 1 If mounting the module on a US amp S equipment rack bolt the base plate in position 2 Solder local signal lines 110 120V ac to socket terminals 1 and 2 on the module 3 S
15. sistor R1 that the release occurs at 5 9V ac input Note The release adjustment can only be checked after the relay has been picked up Remove the Ri decade box and solder IK in an equivalent 1 2W 5 carbon resistor in its place Set the MODE switch to steady Adjust amplifier so that V1 reads 0 00V ac RMS 1 to 91 67 Hz 2 to 7 Hz 420 Set oscillator no and oscillator no code Adjust the amplifier output so that multimeter V1 reads 9 0V ac RMS Set oscillator no 1 to 250 Hz and 6 adjust the amplifier output so that Vi reads 125V ac RMS l to 60 Hz and 7 adjust the amplifier output that Vi reads 150V ac RMS Set oscillator no 1 to 100 Hz and 8 adjust the amplifier output so that Vl reads 9 0V ac RMS Adjust the amplifier for a minimum 9 level Adjust the MOCE switch to the code 20 position adjust amplifier so that Vi reads 1 3 57 ac RMS IJ Verificar the test light shcuid turn The test lignt should on The internal power relay should pick up and the test light should turn orf The test light should remain on The test light should remain on r3 y p test light should tura off The Iight should tura The power relay should release 4 4 COMPONENT SHOP TEST 4 4 1 General Tests on individual subassemblies and ccmsonents of the Dual Frecuency TRU II Code Reset Unit requires removing the cover and all
16. ted Circuit Board Relay Screw 34 40 x 1 4 Pan Head Washer 4 Lock Screw 10 32 x 3 8 Pan Head Washer 19 Lock Washer 10 Flat Nameplate Pop Rivet Wire 20 PVC Blue Wire 20 PVC Red Wire 20 PYC Black Wire 20 PVC Green Wire 20 PVC Brown Wire 20 PVC Yellow Wire 20 PVC Orange Wire 20 PVC Gray Wire 14 PVC Gray Tie Wrap Terminal Terminal Right Angle Plate Mounting Base Terminal Post Washer 3 16 Tlat Nut 514 24 AAR Clamr Screw 5 32 x 1 2 Pan Head Washer 6 Lock Stainless Steel Washer 6 Flac 42 22 1 Refer to section A 2 for component cars USES PART NO 451207 1292 N451227 1701 i 451207 1906 12071878 451496 8503 7525007 1050985 2047681 1048166 N451039 5701 N451039 5702 N451039 4104 N451807 7601 2726153 0157 2507297 0104 2047765 2507266 2047733 2475077 451108 5202 2490029 A045505 0002 A045505 0006 A045505 0001 A045505 0004 A045505 0003 A045505 0009 A045505 0005 A045305 0007 A045519 0005 J703302 3731476 3731399 0073 N451207 1102 M115706 3047500 480301 M3812938 I J507022 J457121 0107 1941996 2048248 _ _ NOTES m Pr e r w icm Hein APER A AA s s ha Wie ieee SJ dion A Vi e OE lt
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