SERVICE MANUAL 4547 - Ansaldo STS
Contents
1. SERVICE MANUAL 4547 SERVICE SPECIFICATION RD RELAYS The Style RD 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 various coil resistances and calibration values are furnished to suit specific applications This service spec ification gives calibration tables and service instructions for Style RD relays Because of the special fixtures required in the assembly of these relays it is recommended that they be returned to the factory when major repairs involving replacement of parts are required However where facilities are available to 7 handle major repairs reference should be made to Service Specification SU 4547 A I COMMON FEATURES RD relays are individually housed with all operating parts fully enclosed and F sealed All contacts are visible through the front cover RD relays have two separate coilcircuits which may be used independently or in combination to suit requirements as shown in Figure 1 NUII SERIES MULTIPLE INGE PENDENT TERMINAL MARKINGS AS FOUND ON RELAY MOUNTING BASE Figur 1 RD R lay Coil Connections RD relays are plug connected for quick and easy replacement Coded key slots are provided in the relay case to mesh with pins in the mounting base thereby preventing insertion of a given relay into an incorrect mounting base The pin plate on each mounti2. In the event any contact member or bias spring becomes unserviceable it should be removed To remove the semi rigid members a force perpendicular and away from the face of the relay should be applied to the member A nail with half its head removed is a convenient tool to use for this purpose To re move the flexible members roll them free of the insert A new member can then be fastened to the relay body inserts by soldering as follows 1 File off all the remnants of the old member until a smooth clean surface results on the insert to which the member was welded and apply a thin film of non corrosive soldering flux 2 With the armature held in mid position clamp the new member in place making sure that the contacts are aligned and that the contact end of the spring has clearance with respect to the nylon rotor 3 Using an electric soldering iron heat the insert and apply solder de pending upon capillary action to carry the solder between the insert and the member The solder should not build up excessively on the member beyond the limits of the insert 4 Clean the excess flux from the joint If a knife is used be careful not to score the flexible springs as this can eventually lead to breakage The references for the replacement members are as follows Flexible Y Spring UN307995 Flexible Single Spring UN307873 Bias Spring UN317482 Semi Rigid Contact Member UN307993 XI CONTACT BOUNCE TEST As a final check of the
3. ENERGIZATION MIN MAX UN308000 66 5 29 33 66 22 0 36 0 UN308003 572 28 18 13 14 22 11 5 15 5 3 S N OL LPSE OS oads aotaras S S TABLE NO 2 Calibration Data For Style RD Relays With Coils Connected in Multiple See Table No 1 for coils connected in series BIASED RELAYS RELAY RELAY RES CHARGE SHOP ADJUSTMENTS LIMITS FIELD LIMITS DROP AWAY PICK UP DROP AWAY PICK UP PIECE NUMBER IN OHMS 10 MILLIAMPS VOLTS MILLIAMPS MILLIAMPS MILLIAMPS MILLIAMPS MIN MAX MIN MIN MAX UN308001 240 6 30 110 120 20 102 130 UN308002 64 99 3 17 18 6 2 6 15 6 20 4 UN315538 168 8 5 6 74 84 4 68 92 UN318614 280 4 5 15 126 140 10 114 154 STICK RELAYS RELAY RELAY RES CHARGE SHOP ADJUSTMENTS LIMITS FIELD LIMITS DROP AWAY PICK UP PICK UP MILLIAMPS MILLIAMPS MILLIAMPS MIN MIN MAX ENERGIZATION MIN MAX o8 66 132 44 12 26 28 44 23 31 PIECE NUMBER IN OHMS 10 UN308000 UN308003 143 LESP NS dedg aotArag
4. Figure 4 7 U S amp S 9 Service Spec SU 4547 In this test some bounce will be observed inall contacts the degree at which this bounce becomes objectionable is illustrated in Fig 5 Contacts which show excessive bounce should be cleaned and checked for spring pressure per Sections V A and VI A Low spring pressure is the primary cause of excessive contact bounce CONTACT CLOSED CONTACT OPEN See SATISFACTORY CONTACT CONTACT CLOSED CONTACT OPEN amaeana UNSATISFACTORY CONTACT CONTACT CLOSED CONTACT OPEN enna UNSATISFACTORY CONTACT Figure 5 TABLE NO 1 Calibration Data For Style RD Relays With Coils Connected In Series See Table No 2 for coils connected in multiple BIASED RELAYS CHARGE SHOP ADJUSTMENTS LIMITS FIELD LIMITS DROP AWAY PICK UP DROP AWAY PICK UP MILLIAMPS MILLIAMPS MILLIAMPS MILLIAMPS RELAY RELAY RES PIECE NUMBER IN OHMS 10 MILLIAMPS VOLTS l MIN MAX MIN MAX UN308001 100 120 12 15 0 59 60 0 10 0 5l 65 0 UN308002 3460 32 110 1 5 8 5 9 3 1 3 7 8 10 2 UN315538 200 84 17 3 0 37 42 0 2 0 34 46 0 UN318614 60 140 9 7 5 63 70 0 5 0 97 77 0 UN386450 2 50 49 0 425 STICK RELAYS RELAY RELAY RES CHARGE SHOP ADJUSTMENTS LIMITS FIELD LIMITS i DROP AWAY PICK UP MINIMUM PICK UP PIECE NUMBER IN OHMS 10 MILLIAMPS VOLTS MILLIAMPS MILLIAMPS SERVICE MILLIAMPS MIN MIN MAX
5. increase the current until the relay picks up in the clockwise direction The current at which the relay armature moves without hesitation from the counterclockwise position to the clockwise position is the normal pick up value If the stick relay calibration does not conform with the values given in Table 1 check the contact adjustments in accordance with Section VI before making the adjustments as follows U S amp S 7 Service Spec SU 4547 Since there are no biasing springs on a stick type relay the adjustment of the strength of the permanent magnet is the chief means used to obtain proper calibration A reduction of permanent magnet strength decreases the required pick up current normal and reverse and an increase of magnet strength raises the required pick up current If the relay cannot be properly calibrated by permanent magnet adjustment alone and the relay armature hangs reduce the pressure in the Y heel springs keeping within the specified limits set forth in Section VI VII CONTACT RESISTANCE After cleaning the contacts as outlined in Section IH individual contact re sistances should be no more than 0 03 ohm with the armature in the picked up or released position IX SERVICE CALIBRATIONS It is recommended that RD relays be removed from service when the cali bration values are beyond the limits suggested in the calibration tables under the heading of Field Limits X CONTACT AND BIAS SPRING REPLACEMENT
6. arged magnet should attract the end of a compass needle which points to geographic South B Aging Reducing Strength 1 Place the magnet on the aging coil as shown in Figure 2 To increase the aging effect per unit ampere in aging coil hold the magnet closer to the center core 2 Adjust the variac for zero voltage 3 Close the A C Switch 4 Increase the a c currentto 5 amps then decrease slowly to zero Open Switch 5 Check magnet on gauss meter 6 If gauss meter reading indicates too strong a magnet age magnet again using a higher value of a c current If gauss meter reading indicates too weak a magnet fully charge magnet again and then age using a lower value of a c current C Application of Magnets to Relay Apply magnet to the relay with the side marked N to the left when facing the magnet and with the magnetic structure extending upward FIXTURE UN327763 GAUSS METER 39 GE CAT NO 416X29 AIR GAP 0 048 RD RELAY MAGNET Figure 3 Use of Gauss Meter Fixture V BIASED RELAY CONTACT ADJUSTMENT A Heel Contact Spring Adjustment All spring pressures should be measured with a gram gage Imtra Corpor U S amp S 4 Service Spec SU 4547 ation UJ620304 10 80 grams or equivalent The gage should be applied to the contact spring next to the contact button on the side toward the weld With gage at right angles to the contact spring the force necessary to lift the spring away fro
7. contact adjustments once again before making the adjustments des cribed below 4 k U S amp S 6 Service Spec SU 4547 If the relay does not meet with the required calibration valuesor if the arm ature hangs in the mid position adjustments must be made to the biasing springs and or the permanent magnet A relay armature is hanging when it fails to move without hesitation from one pole face to the opposite pole face at the re quired pick up or drop away current value given for calibration Hanging on drop away may be caused by a weak permanent magnet insuff icient pressure in the biaSing springs or a combination of the two Hanging on pick up is caused by excessive pressure on the biasing springs When adjusting the biasing springs an effort should be made to maintain nearly equal pressure in each of the two springs In some cases the spring pressure in the Y heel springs and in the single heel springs must be reduced in order to overcome hanging or to obtain proper calibration The pressure in these springs shouldnever be reduced below the 20 grams minimum value when measured as described in Section V The pressure in the Y heel springs and in the single heel springs should be changed to obtain proper calibration only if it is found that allowable adjustment of the biasing Springs and of the magnet strength as described in the following is inadequate to obtain proper calibration An increase of magnet strength
8. continuity characteristics of the relay contacts a contact bounce test is recommended This tes is performed by operating the U S amp S 8 Service Spec SU 4547 relay at approximately 25 cycles sec and then observing the trace of contact make and break on an oscilloscope Dumont Type 340 P1 screen or equivalent The relay can be operatedeither directly from a 25 cycle A C Source or driven at approximately 25 cycles by a30 ohms 30 ohms RD stick type relay calibrated to pick up at 0 053 ampere with the coils in series The wiring and other de tails for the latter arrangement are found in Fig 4 MOUNTING BASE UN308766 FOR DRIVING RELAY 30 OHMS 30 OHMS RD STICK TYPE CALIBRATED TO PICK UP AT 0 053 AMPERE WITH COILS IN SERIES MOUNTING BASE UN308766 WITH INDEXING PINS VOLTAGE A REMOVED FOR RD RELAY UNDER TEST FOR CONTACT a BOUNCE VOLTAGE 8 i ee a SWITCH A EACH FRONT AND BACK CONTACT TO BE WIRED TOA VOLTAGE C POINT ON SWITCH B O 2 i TO O OSCILLOSCOPE re 45 VOLT ORY CELL ve 0 SWITCH B 0 VOLTAGE A D C SUPPLY VOLTAGE IOV FOR ALL RELAYS QO fe EXCEPT UN30B002 WHICH REQUIRES 50V VOLTAGE B ADJUSTABLE VOLTAGE ADJUSTED TO o oO o OPERATE RELAY UNDER TEST lo VOLTAGE C MAINTAIN AT APPROXIMATELY 6 4 V DC een a eee ee SWITCH A OPEN FOR BIAS RELAYS CLOSED FOR STICK RELAYS SWITCH B SELECTOR SWITCH SELECTS CONTACT TO BE TESTED
9. d to connect the relay coils in series is used to check relay calibration values Voltage d c is applied to the test fixture from a potentiometer and the current is measured witha milliammeter in the positive coil lead to the fixture Set the potentiometer for a low output voltage Throw the two top switches on the fixture up and the bottom switch to the right Positive polarity should now appear on the top right hand receptacle of the fixture and negative polarity should appear on the lower left hand receptacle Plug the biased relay into the fixture Increase the voltage until the current reaches the value given under Charge in Table 1 The relay armature should now be in the clockwise or picked up position Decrease the voltage until the relay armature drops away to the count erclockwise position The current at which the armature moves from the clock wise position to the counterclockwise position is the drop away value Momen tarily open the circuit by throwing the bottom switch to the left and returning it to the right Gradually increase the voltage until the relay armature moves once again to the clockwise position The current at which the armature moves from the counterclockwise position to the clockwise position is the pick up value These current values must agree with the values given in Table 1 for proper relay calibration If the relay calibration does not conform with the values given in Table 1 check the
10. m the nylon rotor should be measured This force should not be less than 20 grams nor more than 24 grams To check the pressure of the flexible Y heel springs insertgages UM372029 at each end of the armature with the side of the gage marked bias on the same Side as the higher stop pin These gages hold the armature in mid position while the pressures of the Y springs are checked All contacts should be open during this check If necessary the semi rigid contact fingers should be bent to just open the contacts If a Y Spring is found to have too little pressure the pressure can be in creased by opening the vertex of the Y spring with a metal rod 1 16 diameter Pressures can be reduced by closing the vertex with a pair of tweezers Care should be exercised to avoid permanently distorting the Y springs If there is a marked unbalance between the pressures on the two sides of an individual spring bend the Y spring at a point adjacent to the Supporting stem in a direction which will equalize the pressures The single flexible springs are checked with the gages removed andthe arm ature in the released or counter clockwise position viewed from the frontof the relay Pressures on the single flexible heel spring can be adjusted by bending them slightly at the support All bending should be done with a contact spring bender B Back Contact Adjustment Back contacts those which are made when the armature is in the counter cl
11. ng base contains five pins in various combinations Each separate type of RD relay has an individual combination assignment Slots are milled in the base of each relay to match this assignment The numbers which remain on the base of the relay after the slots have been cut identify the a code combination for that relay k March 1959 UNION SWITCH amp SIGNAL DIVISION Rev 7 83 AMERICAN STANDARD INC SWISSVALE PA 15218 PRINTED IN USA U S amp 5 2 Service Spec SU 4547 II OPERATION Two different types of relay operation are provided namely magnetic stick or biased The stick type relay red name plate requires a polarity reversal to actuate the armature to operate the relay The relay armature will remain in its last operated position until a d c voltage of polarity opposite to that which was last applied is used to energize the relay The armature of abiased type relay picks up moves clockwise only when a d c voltage of a given polarity is applied When a biased relay is either de energized or energized by a voltage opposite the given polarity the armature will remain in the counter clockwise de energized position or return to this position if picked up M CLEANING All foreign matter should be removed from the interior of the relay paying particular attention tothe contacts and armature stop pins For general cleaning a small dry fine bristled camel s hair brush may be used C
12. ockwise position should be adjusted using gages UM372032 With the relay face down and turned So that the permanent magnet side of the relay is the near side place the gages between the armature and the pole faces Insert the gages on either end of the armature so the side marked Bias B of the right gage is on the far side and the side marked Bias B of the left gage is on the near side Plug the relay into fixture UN322799 which is essentiallyan RD relay mount ing base equipped with contact indicating lamps Usinga spring bender UR375786 applied near the welded end of the semi rigid back contact member bend the member so that both of its contact buttons just make with bothof the corresponding Y heel spring contact buttons If both of the contacts do not make simultaneously use the narrow slotted end of tool UM375775 to bend the post to which the con tacts are welded just enough to align the contacts vertically If necessary to raise or lower the Y spring contacts use the wide slotted end of the tool to bend the post A lamp will indicate when the Y heel spring is made with either a front or back contact The contact is properly adjusted when a light touch on the semi rigid member extinguishes the lamp C Front Contact Adjustment After the four back contacts have been adjusted remove the relay from the fixture and remove the gages from the relay Now insert gages UM372031 with the side marked Bias F op
13. ontacts and stop pin surfaces may be cleaned by brushing lightly with a clean fine bristled brush moistened with clean denatured ethyl alcohol and then drying immediately with a Strip of clean lintless cloth tape IV PERMANENT MAGNET Magnet Charger UO340001 may be used to charge or age reduce the strength of the permanent magnets Fixture UN327763 together with Gauss Meter Gen eral Electric Cat 416X29 can be used to measure the magnet strength The initial permanent magnet strength should be approximately 90 gausses for biased relays and 80 gausses for stick relays It is permissible to increase or decrease the magnet strength if necessary to obtain proper calibration values ADAPTER 2 PERMANENT UM320079 MAGNET CHARGING COIL LARGE AGING COIL SMALL VARIAC TRANSFORMER OR POTENTIOMETER oo Qoan HOV HOV D C AC name ed 5 AMPS AC Figure 2 Use of Magnet Charger A Charging 1 Place magnet on charger as shownin Figure 2 with end marked N on U S amp S 3 Service Spec SU 4547 charging coil 2 Close 110 V D C switch for 2 or 3 seconds then open Repeat leave Switch open 3 Check magnet strength by applying magnet to the gauss meter fixture as Shown in Figure 3 The reading should be no less than 100 gausses Actual magnet strength is much higher since the fixture is arranged to measure only a part of the total flux 4 The endmarked N of a properly ch
14. posite to the position given above for the side marked Bias B of the back contact gages Plug the relay into the fixture and U S amp S 5 Service Spec SU 4547 adjust the eight semi rigid front contact members in the same manner as des cribed for the back contacts Care must be exercised when bending the semi rigid front contact members adjacent to the bakelite cross members which support the front pivot Pressure exerted by the bending tool against the bakelite might cause breakage D Contact Openings After the contacts have been adjusted remove the relay from the test fix ture and insert the same gages UM372029 that were used for adjusting the flexible Y heel springs Section V A All contacts should be open by approxi mately 0 002 inch VI STICK RELAY CONTACT ADJUSTMENT A Heel Contact Springs should be adjusted the same as outlined in Section V A except that gages UM372028 should be used to position the armature B Reverse Contacts should be adjusted the same as outlined in Section V B back contacts of biased relay using gages UM372030 marked Stick C Normal Contacts should be adjustedthe same as outlined in Section V C front contacts of biased relay except using gages UM372030 marked Stick D Contact Openings should be checkedthe same as outlined in Section V D except using gages UM372028 VII CALIBRATION A Biased Relays Test fixture UN334998 which is wire
15. raises the pickup value and decreases the drop away current value A decrease in magnet Strength has the opposite effect on relay operation An increase in the biaSing spring pressure raises both the pick up and the drop away current values A decrease in biaSing spring pres sure has the opposite effect on relay operation B Magnetic Stick Relays The same test fixture UN334998 is used for calibrating both biased and magnetic stick type relays Set the potentiometer for low output voltage and throw the two top switches down and the bottom switch tothe left Positive polarity should appear on the lower left hand receptacle of the fixture and negative po larity Shouldappear on the upper right handreceptacle Throw the bottom switch to the right and the polarity should reverse Leave the switches in this position Plug the stick relay into the test fixture Increase the currentto the value given under Charge in Table 1 and then gradually reduce the current to zero Throw the bottom switch to the left and gradually increase the current until the relay picks up in the counterclockwise direction The current at which the relay armature moves without hesitation from the clockwise position to the counterclockwise position isthe reverse pick up value Continue to increase the current until the value given under Charge is reached and then gradually reduce the current to zero Throw the bottom switch to the right and gradually
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