Magnetic Stick, D.C. Plug-In Relay PP-151
Contents
1. Relay Only SM 4596G Rev 1 May 2008 ay 4 AnsaldoSTS Union Switch amp Signal 5 PARTS LIST Parts List Table 5 1 PP 151 Magnetic Spick DC Relay PNs N322507 701 703 N322516 701 N438007 802 804 See Figure 5 1 ITEM NUMBER DESCRIPTION PART NUMBER 7 Armature Bracket PN 159B M436773 8 Armature N437638001 11 Contact Block N438627 14 Pull Handle Aluminum J561111 22 Molded Relay Cover 4776596 Encapsulated Coil Relay N322507 701 240 ohm N333975 24 Relay N322507 703 25 ohm N379650 Relay N322516 701 240 ohm N333975 Relay N438007 802 400 ohm N321647 Relay N438007 804 400 ohm N433498 40 Magnet Permanent M437642 41 Magnet Permanent M437891 42 Arm Operating M373632001 44 Latch Rod M388888 46 Latch Machined M321728 50 Indicator Arm M432380 SM 4596G Rev 1 May 2008 5 1 EY 4 AnsaldoSTS Parts List Union Switch amp Signal Pa 0900 0009000000 i Figure 5 1 PP 151 Magnetic Stick DC Relay 5 2 SM 4596G Rev 1 May 2008 ay 4 AnsaldoSTS Union Switch Signal Parts List Table 5 2 Car Carried PP 151 Magnetic Stick DC Relay PN N437657 See Figure 5 2 ITEM NUMBER DESCRIPTION PART NUMBER 1 Relay Frame M437648 7 Armature Bracket PN 159B M436773 8 Armature N437638001 11 Contact Block N438628 14 Pull Handle Aluminum 3561111 22 Molde2. 2 4 2 4 RELAY INSERTION ura A veil add dea ity i eta A 2 4 2 44 Wayside Relays ora ads 2 4 2 4 2 Car Carried S UT 2 5 3 FIELD MAINTENANCE 5 aT shee Sat ceca ob ieee acta ae ae aeaa aaae Aa ea aa ae aa aeoieo iade iit 3 1 3 1 PERIODIC PERFORMANCE TEST Teien eiad neiaa anadi ORSR TAD 305 3 1 O ae THH A Be 3 1 3 1 2 Service Requirements see eee eee eee cece eee eee eee 3 1 L SHOP MAINTENANCE iio cescccsscccate ccs sccceesecaceccecusccssoceadecuesesccss sccedecuecusdiued detveduecds scucesquotusbedecoeweeetacs 4 1 4212 INTRODUCTION ta oe nA eee ie eth eel Aeon et natal apie 4 1 4 2 CLEANING AND INSPECTION 2 sss eee eee 4 1 4 21 Armature Stop Cleaning TTT 4 1 4 2 2 Cleaning Relay Contacts sees eee eee eee 4 2 4 3 CHECK OUT PROCEDURE Performance Tes sss sees eee 4 3 4 4 REPAIRS AND REPLACEMENT 4 3 4 4 1 Recommended Tooli siaa inei Aea ei a aE a ta iE A E aA 4 3 442 R la 4 3 4A 3 Ae 4 4 4 5 ADJUSTMENTS TTT 4 5 4 5 1 Recommended Tools and Test Equipment sss sese eee eee eee eee 4 5 4 5 2 Armature Alamillo ida 4 5 4 5 3 Permanent eT acess ies ites raaa aAa AE AAE E a AE SATARE 4 6 ASA Armature OKE ro nde oia 4 6 4 5 5 MACO 19 He a a a R d dO a aL 124 4 6 A256 AC OMLACIS H ato loto al 4 7 4 6 CALIBRATION sie center Sah wh Aiea das Ae a ed ak i hi 4 8 SM 4596G Rev 1 May 2008 iii 7 AnsaldoSTS Table of Contents Union Switch amp Signal 4 6 1 Recommended Test Equipment sss esse es sese esse esse
3. Neuses Co No N318 Heavy Duty J397187 001 Paper Strip strips cut from 67 pound white Springhill Vellum Bristol Paper J793094 pkg of 50 Also recommended Recommended Cleaning Materials Order Reference Emery Paper Wet or dry 600 Grit cut in strips Commercially Available Stop Pin Conditioning Graphite Stick N451151 3203 4 2 1 Armature Stop Cleaning The following instructions are for cleaning the armature stop pin see Figure 4 1 This procedure should be followed wherever a relay is shopped for failure to meet its calibration specifications during scheduled field inspection and tests SM 4596G Rev 1 May 2008 4 1 DN 4 AnsaldoSTS Shop Maintenance Union Switch amp Signal a C Insert a clean paper strip J793094 between the stop pin and relay pole face Using moderate pressure to hold the armature closed pull the cleaning strip back and forth in a circular motion over the stop pin Continue this process until it is apparent that no foreign substances are being transferred to the strip The next step is to apply a dry lubricant such as graphite to the relay stop pin and its point of contact on the pole face 1 Insert the Stop Pin Conditioning Graphite Stick between the armature stop pin and its point of contact on the pole face with graphite against stop pin While applying moderate pressure on the stick pull the stick back and forth and in a circular motion over the stop pin continuing several s
4. amp Signal D Y AnsaldoSTS Union Switch amp Signal 1 4 SM 4596G Rev 1 May 2008 A 4 AnsaldoSTS Union Switch amp Signal Installation 2 INSTALLATION Relays plug directly into a mounting base which is secured to a rack The only installation instructions required are for the mounting base 2 1 Mounting Base Secure the mounting base directly to the rack using the hardware furnished All wiring terminates at the rear of the mounting base to solderless terminals receptacle contact springs Mounting base details are shown in Figure 5 3 Old Style Base and Figure 5 4 Improved Base of the Appendix 2 2 Relay Indexing Relays are factory equipped with indexing pins to prevent insertion of an incorrect relay into a mounting base Each relay is accompanied by an indexing plate which is applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with indexing plate is shown in Figure 2 1 The following data defines the indexing that has been established for relays covered by this manual a The index code always consists of four figures such as 0001 0002 or 0101 and is used for both the relay and the indexing plate on the mounting base b The index code for each relay can be determined from the relay part number and its suffix which is marked on the name plate attached to the front of the relay The first two digits of the index code are the last two
5. digits of the part number and the second two digits of the index code are the last two digits of the suffix The index number thus obtained should agree with the placement of the indexing pins in the numbered vertical rows on the back of the relay starting with the top pin and reading down c The index code for each mounting base is determined by the placement of the holes in the numbered vertical rows of the large white nylon indexing plate which is affixed to the front of the mounting base This indexing plate should not be removed from the mounting base unless it is damaged or the indexing is to be purposely changed to accommodate a relay of a different part number Discard the indexing plate which comes in a bag tied to the handle of all new relays unless it is needed for replacement of damaged indexing plate or for application to a new mounting base SM 4596G Rev 1 May 2008 2 1 DN 4 AnsaldoSTS Installation Union Switch amp Signal WARNING Never drill new holes in a base indexing plate which will permit application of relays with different part numbers or change indexing pins on the back of a relay unless it is being converted to a new part number Otherwise a hazard will be created which may compromise safety circuit functions 2 3 Receptacle Contact Springs 2 3 1 Old Style Base Only The mounting base will normally be equipped with the required quantity of J680165 solderless receptacle contact springs and
6. essere neee ereer neee 4 8 A62 Polary ici e Rees ee A he each ee at ag dee ack eee 4 8 36 3 IP see T 4 8 4 6 4 Armature Travel sees eenn 4 9 4 6 5 Special TOS bienal A 4 10 4 7 CALIBRATION REQUIREMENTS 0 cc cccccecsccccseccecesseeeeeeecseeeeeeseeeeeesseneeeessensaeeeseesaeess 4 10 4271 Hold DOWN TOF QUO wis ec ies acct a vinccea oaan dll el dll dd db 4 10 4 1 2 Contact a ae 4 10 5 VPAR TS LIST Sareri E ASE AA A soasbods page bads AR 5 1 6 RAIL TEAM AND TECHNICAL SUPPORT ssssss sss ee sss vesse reenn e ennenen neee ennenen nenes 6 1 iv SM 4596G Rev 1 May 2008 o Y 77 AnsaldoSTS Union Switch amp Signal Table of Contents List of Figures Figure 2 1 Typical Plug In Relay and Mounting Base sese sese eee eee eee 2 3 Figure 2 2 Receptacle Contact Spring installed sese eee 2 3 Figure 2 3 External Connections to Mounting Base sese sese ee eee ee 2 5 Figure 4 1 Armature stop Pin Reece 4 2 Figure 4 2 Assembly of Permanent Magnet see eee eee 4 6 Figure 4 3 PP 151 Relay Test Circuit 2 0 ccc ceeeccecceeceeeceeeeeeeeeeeneseeneeecesoeesseesaeeeseesaeesanecseeeseeeseaseneteneees 4 9 Figure 4 4 Circuit for Special Tests se eser ereenn ereenn nenen ee 4 10 Figure 5 1 PP 151 Magnetic Stick DC Relay eee eee 5 2 Figure 5 2 Car Carried PP 151 Magnetic Stick DC Relay eee eee eee 5 4 Figure 5 3 Old Style Mounting Base for PP 151 BRelavsa sss eee eee eee eee eee eee 6 Figure 5 4 Improv
7. paper strip between the open contacts then close the contacts and withdraw the paper strip f Repeat step f several times if necessary 4 2 2 2 Contacts with Heavy Tarnish Slightly Rough or Pitted a Perform the procedure in paragraph 4 2 2 1 Steps b to f 4 2 2 3 Contacts with Surface Film or oxidation Not Pitted a Perform the procedure in paragraph 4 2 2 1 Steps e and f 4 3 CHECK OUT PROCEDURE Performance Test Perform calibration in accordance with paragraph 4 6 4 4 REPAIRS AND REPLACEMENT Since the contacts and armature bushings are the only wearing parts in this relay in most cases the relay can be restored to proper operation by dressing Paragraph 4 2 2 and readjusting paragraph 4 5 6 3 the contacts or repairing the armature 4 4 1 Recommended Tools Twist Drill 42 Screw Driver Torque Measuring 4 4 2 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the parts list appendix for part information and location of parts In general to dismantle the plug in relay proceed with the following sequencer SM 4596G Rev 1 May 2008 4 3 aJ l AnsaldoSTS Shop Maintenance Union Switch amp Signal a Remove relay cover seal b Carefully remove plastic cover c Remove disassemble relay components as required d Remove contacts contact block as required e Remove permanent magnet only if required NOTE These magnets are of a special alloy that
8. permits retention of proper strength indefinitely if not abused When not in place on relays magnet assemblies should be kept separated from other magnetic objects and the screws which hold the extension to the magnet be kept tight Should a magnet become weakened it should be returned to the factory for recharging by the special equipment required to fully charge the magnet It will then be aged to its best working strength 4 4 3 Reassembly Reassembly is accomplished generally in the reverse order of disassembly The following paragraphs provide additional instructions to be followed during reassembly of this relay 4 4 3 1 General Parts Replacement Do not over tighten of force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in paragraph 4 6 4 4 3 2 Replacing Contact Block If the contact block is to be replaced by another remove the old block then use a small punch to remove the small dowel pins Attach the _new block with the four screws Torque the contact block screws to 10 2 inch pounds Run a 42 drill 0 0935 Dia thru the dowel pin holes into the epoxy contact block for a total depth of 9 16 1 32 0 NOTE Replacement contact blocks MUST be of the same general design Carefully install the dowel pins tapping in until they are flush with the surface 4 4 SM 4596G Rev 1 May 2008 4 AnsaldoSTS Union Switch amp Signal Shop M
9. relays as given in paragraph 4 6 3 2 SM 4596G Rev 1 May 2008 4 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 SHOP MAINTENANCE 4 1 INTRODUCTION This section provides the information necessary to perform shop level repairs of the PP 151 relays covered in this manual In general relays arriving at the shop for repair have been checked in the field and have been found to perform unacceptably or have been physically damaged 4 2 CLEANING AND INSPECTION Before inspecting the relay and initiating repairs use a soft cloth to clean the exterior carefully to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc Inspect the relay exterior 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 physical damage Remove the cover and proceed with stop pin and relay contact cleaning using the following recommended cleaning materials Recommended Cleaning Materials Order Reference A relay contact cleaning kit part number X451646 0901 is available that consists of the following three items or which may be ordered individually Burnishing Tool P K Neuses Co No 3 316 J397187 Burnishing Tool P K
10. will accommodate one or two 14 16 wires It can however be equipped with receptacle contact springs for one or two 10 12 wires J680181 or for one or two 18 20 wires J680179 Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation 2 3 2 Improved One Piece Base Only The one piece mounting base with hardware N451376 0302 includes a full complement of receptacle contact springs M451142 2702 to accommodate one or two 14 16 wires mounting fasteners and tags It can however be equipped with receptacle contact springs for one or two 10 12 wires M451142 2703 or for one or two 18 20 M451142 2701 Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation Each solderless receptacle contact springs should be inspected for physical damage and straightness before proceeding with installation The following checks are recommended when installing solderless receptacle contact springs a Receptacle contact springs must be inserted into the base with the lock side down Refer to Figure 2 2 b Make certain that the lanced tab is slightly compressed as the receptacle contact spring is inserted along the top of the cavity The lanced tab could have been bent during handling and therefore would not provide the required contact pressure after the relay is inserted If the lanc
11. 2008 NA n 7 AnsaldoSTS Rail Team and Technical Support Union Switch amp Signal 6 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam switch com SM 4596G Rev 1 May 2008 6 1 D 4 AnsaldoSTS Rail Team and Technical Support Union Switch amp Signal DN Y AnsaldoSTS Union Switch amp Signal 6 2 SM 4596G Rev 1 May 2008
12. Service Requirements 3 2 2 1 General All vital relays must be inspected and tested at least once every four 4 years The tests and inspections are to include pick up current drop away current timing of slow operating and timing relays and visual inspection of contacts for damage or misalignment corrosion or other contamination of parts loose parts inside of the cover broken seal and cracked or broken cover All vital relays installed in locomotive or car carried equipment are to be removed from service and adjusted repaired and tested at least once every six 6 years Relays not passing the above stated tests and inspections must be replaced and not returned to service until the operating characteristics and conditions are in accordance with US amp S specifications 3 2 2 2 In Service Test It is recommended that line relays in service be removed from service for shop repairs when one or more of the following conditions occur Use as a reference the calibration values given in Table IT a Pick up is more than 110 of the new relay value b Normal and reverse pick ups differ so that the lower value is less than 70 of the higher value c The armature fails to complete its stroke on the special test Par 4 6 5 on relays with single wound coil SM 4596G Rev 1 May 2008 3 1 DN 4 AnsaldoSTS Field Maintenance Union Switch amp Signal 3 2 2 3 Test Procedures Test the operating characteristics of the PP 151
13. aintenance If it is necessary to install a used contact clock from another relay remove only one of the dowel pins from the aluminum frame Carefully press the block on the remaining pin and fasten in place with the screws One dowel pin will adequately hold the block in place Do not over tighten or force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in paragraph 4 6 4 4 3 3 Permanent Magnet The polarity of the magnet should be such that the top end farthest from the two notched holes will attract the end of a compass needle which points toward geographic South The permanent magnet assembly should be applied to the relay as shown in Figure 4 2 making sure that the magnet is touching the pole piece Tighten the two long screws holding the magnet assembly to the pole piece sufficiently to straighten the curved strap against the magnet Bend the nut locks securely up against the sides of the screw head after the adjustments are made 4 5 ADJUSTMENTS All adjusting and testing must be done with the relay in its normal operating position 4 5 1 Recommended Tools and Test Equipment Item Part Number Gap Gauge 0 001 in to 0 200 in Commercially Available Gram Gauge 0 400 Grams Commercially Available Bending Tool Commercially Available 4 5 2 Armature Air Gap The physical air gap at the center of each armature tip shall be as close as possible to a nominal 0 017 at the ce
14. al Test 4 7 CALIBRATION REQUIREMENTS 4 7 1 Hold Down Torque After the relay has been adjusted to meet calibration requirements the force required to move the armature away from either permanent magnet extension should be approximately 420 grams This value should be measured at the bottom and center of the molded driver and is the upward force in grams required to move the armature away from the permanent magnet When measured the value must not be less than the value given in Table 4 2 4 7 2 Contact Resistance Resistance of front contacts should be measured with the armature in its full stroke position and resistance of back contacts should be measured with the armature fully released Cleaned contact resistance should not exceed the following values Type of Contacts Front Contacts Back Contacts Silver to Silver Impregnated Carbon 0 09 ohms 0 18 ohms Silver to Silver 0 03 ohms 4 10 SM 4596G Rev 1 May 2008 aS 4 AnsaldoSTS Union Switch amp Signal Shop Maintenance Table 4 2 Table Adjustment and Calibration Values for PP 151 Relay Test Permanent Magnet Assembly Reverse Contact Adjustment front Normal Contact Adjustment back Normal Contact Adjustment back Contact Openings Contact Openings Reverse amp Normal Contact Openings Polarity Test Table II Polar Pick up and working Normal and Reverse Difference Special Test Using circuit of Figure 4 4 All contacts Hold Dow
15. ber as shown in Item 1 when ordering the complete base SM 4596G Rev 1 May 2008 5 5 y a AnsaldoSTS Parts List Union Switch amp Signal nooo Que E U L w E w u w Figure 5 3 Old Style Mounting Base for PP 151 Relays 5 6 SM 4596G Rev 1 May 2008 ay 4 AnsaldoSTS Union Switch amp Signal Parts List Table 5 4 Parts List for Improved Mounting Base See Figure 5 4 Item Part No Description la N451376 0302 Base Complete for Wayside Relays See Note 1b N451376 0301 Base Only tc N451376 0303 Base Complete for Car Carrying Relays See Note 5 M451152 2702 Receptacle Contact Spring When mounting base complete is ordered a bag of parts is included in the inner NOTE carton with the mounting base and instruction prints The bag contains tags screws washers and nuts which are used for attaching the mounting base to the rack The receptacle contact springs that are normally included are M451142 2702 for 14 and 16 wire If a different wire size is used the appropriate part number should be specified when ordering the complete base M451142 2701 for 18 20 wire or M451142 2703 for 10 12 wire If solderless receptacle springs are needed order M451 142 2703 SM 4596G Rev 1 May 2008 5 7 Ss 4 AnsaldoSTS Parts List Union Switch amp Signal Figure 5 4 Improved Mounting Base for PP 151 Relays 5 8 SM 4596G Rev 1 May
16. d Relay Cover 4776596 24 Encapsulated Coil N436791 40 Magnet Permanent M437642 41 Magnet Permanent M437891 42 Arm Operating M373632001 44 Indicator Arm M432380 SM 4596G Rev 1 May 2008 5 3 77 AnsaldoSTS Parts List Union Switch amp Signal 76543 3835533858 0000000000 oc000000000 0000000000 ROWA gt sS D 4A1 0023 00 Figure 5 2 Car Carried PP 151 Magnetic Stick DC Relay 5 4 SM 4596G Rev 1 May 2008 ay 4 AnsaldoSTS Union Switch amp Signal Parts List Table 5 3 Parts List for Old Mounting Base See Figure 5 3 Item Part No Description N341785 Base Wayside N437090 Base Car Carried la J680179 Receptacle Contact Spring Solderless Type 18 to 20 Wire 1b J680165 Receptacle Contact Spring Solderless Type 14 to 16 Wire 1c J680181 Receptacle Contact Spring Solderless Type 10 to 12 Wire 17 N322965 Meter Test Plug Insulated Test Plug For opening any coil or contact circuit for removing 19 9077931 receptacle springs When mounting base complete is ordered a bag of parts is included in the inner carton with the mounting base and instruction prints The bag contains tags screws and washers which are used for attaching the mounting base to the rack Also included the required quantity of receptacle contact springs solderless J640165 for 14 to 16 wire If a different wire size is used request the proper part num
17. econds to ensure a sufficient amount of graphite transfer 2 It is not necessary to observe significant deposits of graphite since most of what is required can only be determined by means of a microscope Recheck relay calibration and prepare relay for return to service 4 2 2 Cleaning Relay Contacts This section covers recommended methods for the preparation and cleaning of relay contacts After contacts have been dressed and or after adjustments have been made to meet calibration requirements the contacts should be cleaned in accordance with the following procedure NOTE When using the paper strip clean the back contacts first and then the front contacts last Discard the paper strips when dirty Ml PIN POLE PIECE A STOP PIN MAGNET MAGNET EXTENSION i ARMATURE ASSEMBLY Figure 4 1 Armature stop Pin Location SM 4596G Rev 1 May 2008 ay 7 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 2 2 1 Contacts that are Severely Burned a Using a 600 grit emery paper strip folded with the grit side out so that both contacts can be burnished simultaneously stroke the contacts in the direction of contact wipe b Using the burnishing tool stroke the contacts several times in the direction of contact wipe c Place the paper strip between the open contacts then close the contacts and withdraw the paper strip d Repeat step c several times if necessary e Place the
18. ed Mounting Base for PP 151 Relays sees ee eens eee ee 5 8 SM 4596G Rev 1 May 2008 V gt 7 AnsaldoSTS Table of Contents Union Switch amp Signal List of Tables Table 4 1 Recommended Test EQuipMment ec es essere seeee sees essere ereenn 4 8 Table 4 2 Table Adjustment and Calibration Values for PP 151 Relay eee eee eee eee eee ee 4 11 Table 4 3 Table Il PP 151 Polar Relay Calibration values ee eee eee eee ee eee 4 12 Table 5 1 PP 151 Magnetic Spick DC Relay PNs N322507 701 703 N322516 701 N438007 802 804 See Figures aan cia 5 1 Table 5 2 Car Carried PP 151 Magnetic Stick DC Relay PN N437657 See Figure 5 2 5 3 Table 5 3 Parts List for Old Mounting Base See Figure 5 2 eee eee 5 5 Table 5 4 Parts List for Improved Mounting Base See Figure B 41 sse eee 5 7 vi y SM 4596G Rev 1 May 2008 4 AnsaldoSTS Union Switch amp Signal General Information 1 GENERAL INFORMATION This manual provides service information for the PP 151 magnetic stick de plug in relay The design of the PP 151 relay conforms to all applicable Association of American Railroads AAR specifications 1 1 Description The PP 151 relay is a dual magnetic stick relay which stays in the last operated position after control energy is removed Full contact pressure is maintained during de energization to ensure circuit continuity There are two types of PP 151 relays wayside and car carried The ways
19. ed tab does not touch pull it up slightly using fingers or a suitable tool c After insertion pull firmly on the wire to make certain the receptacle contact spring is locked in the receptacle 2 2 SM 4596G Rev 1 May 2008 Ss 4 AnsaldoSTS Union Switch amp Signal Installation INDEXING PINS INDEX PLATE MOUNTING BASE Figure 2 1 Typical Plug In Relay and Mounting Base RECEPTACLE CONTACT SPRING 4 RECEPTACLE TANINSA CONTACT SPRING LOCK SIDE LOCK SIDE OLD MOUNTING BASE IMPROVED MOUNTING BASE Figure 2 2 Receptacle Contact Spring Installed SM 4596G Rev 1 May 2008 2 3 aJ 7 AnsaldoSTS Installation Union Switch amp Signal 2 3 3 Installing Wires in Receptacle Contact Springs Use the following procedure to ensure a good electrical and mechanical connection between the conductor wire and the receptacle contact spring The following table identifies the correct crimping tool to be used when installing wires in receptacle contact springs ree Old Style Improved Base cee Wire Size Receptacle Receptacle contact Spring Contact Spring J397138 10 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Standard 19451 142 2702 J397188 18 20 AWG J680179 M451142 2701 a Strip 3 16 in 0 187 in or 0 47 cm of insulation from the end of the wire b Place the receptacle contact spring into the jaws of the prop
20. edure a Plug relay into appropriate mounting base on test stand b Check heel springs for bow and adjust as required c Place contact driver in position on relay d Insert reverse front contact open spacer nominal 0 045 inch per Table I Test 2a over the front stop pin and hold firmly by energizing the relay with reverse polarity e Adjust the reverse Front contacts to just open f Replace the reverse front open spacer with the reverse closed spacer 0 040 inch per Table I Test 2b The contacts should be just closed SM 4596G Rev 1 May 2008 4 7 ES 4 AnsaldoSTS Shop Maintenance Union Switch amp Signal g Insert the normal back contact open spacer nominal 0 045 inch per Table I Test 3 over the rear stop pin and hold firmly by energizing the relay in the normal direction h Adjust the normal back contacts to just open i Replace the normal back open spacer with the normal closed spacer 0 040 inch per Table 2 Test 4 The contacts should be just closed j Remove the operating arm using Tool N451151 2801 There should be 0 010 inch opening at the normal and reverse contacts k Repeat Steps c through i and check that the contacts are just open on the contacts open spacer and just closed on the contacts closed spacer 1 Check that when the contacts are just closed the opposite contacts are open at least 0 020 inch m Check that when the stop pin is against the pole piece the opposite con
21. er crimping tool When using only one terminal of any wire size use the shortest terminal c Partially close the crimping tool jaws against the receptacle contact spring to hold it in place Do not crush the receptacle contact spring barrel at this time d Insert the stripped end of wire all the way into the receptacle contact spring barrel Squeeze the tool handles until crimping is completed and the jaws release When using both terminals it is more convenient to attach the first wire to the longest terminal e Remove the crimped receptacle contact spring from the tool and inspect the connection Make certain that the wire is flush with the crimped barrel and that there are no loose strands of wire 2 3 4 Base Wiring for Wayside or Car Carried Relays Some PP 151 relays can be used either in wayside or car carried applications For externally wiring the mounting base see Figure 2 3 2 4 RELAY INSERTION 2 4 1 Wayside Relays Orient the relay to the mounting base with the push rod to the left hand side then plug the relay into the base The relay should be pushed firmly against the mounting base while depressing the latch rod After the relay is completely seated in the base release the latch rod and pull on the handle to ensure that the relay has locked in place 2 4 SM 4596G Rev 1 May 2008 7 AnsaldoSTS Union Switch amp Signal 2 4 2 Car Carried Relays Installation Secure the relay to the mounting base
22. ide type is designed for use in polar control indication circuits and switch control The switch control relay is used in conjunction with or to control type PN 150BM relays The PP 151 relay has two permanent magnets and an armature which is pivoted in the center The relay is factory calibrated to operate across a wide environmental range All moving parts are enclosed in a sturdy transparent dust and moisture resistant cover To ensure the relay is inserted in its proper mounting base all relays have indexing pins Relays lock securely into the plug in position 1 1 1 Coils Coil resistances of PP 151 relays are as follows a car carried 400 400 ohms b wayside 25 240 and 400 ohms Refer to paragraph 1 2 1 to correlate part numbers to coil resistance values The resistance selected depends on the system voltage and circuitry 1 1 2 Contacts Contacts of PP 151 relays are 6 normal and reverse silver to silver impregnated carbon except for the wayside switch control type relay which has 4 normal and reverse silver to silver impregnated carbon and 2 normal and reverse silver to silver 1 2 SPECIFICATIONS The following paragraphs provide the electrical and mechanical specifications of the PP 151 magnetic stick relays covered in this manual 1 2 1 Electrical Relay electrical specifications are tabulated below SM 4596G Rev 1 May 2008 1 1 DN 4 AnsaldoSTS General Information Union Switch amp Signal Mi
23. ll be a minimum of 0 170 and maximum of 0 190 measured at the stop pin Care should be taken that the armature is not permitted to touch or approach closely the engaging faces of both permanent magnet extensions at the same time It is possible that such improper handling would decrease the residual magnetism of the permanent magnets If necessary in order to meet calibration requirements the permanent magnet extensions may be raised or lowered It will be permissible to change this air gap using spacers between the limits of 0 008 to 0 018 POLE PIECE so Pr O pa z MAGNET MAGNET EXTENSION ARMATURE ASSEMBLY Figure 4 2 Assembly of Permanent Magnet 4 5 5 Indicator Adjustment of the armature position indicator after calibration should be made so chat the bottom of the painted surface is viewed from the front of the relay with rover applied and the indicator should be in full view with the armature in the normal position and should be hidden with the armature in the reverse position 4 6 SM 4596G Rev 1 May 2008 7 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 5 6 Contacts Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive loading or an accidental short through the contacts In case contacts must be dressed and or after adjustments have been made to meet calibration requirements clean the contacts in accordance with the instruction
24. n Part No Part No With Without Contacts i i P U Front Testing Front Testing Working working Volts volts N322507 701 6 NR SIC N322507 703 6 NR SIC N322516 701 4 NR SIC 240 2 NR Sil N438007 802 6 NR SIC 400 N438007 804 6 NR SIC 400 N437657 6 NR SIC 400 400 Note 1 Wayside Relay normally used in series with other relay for polar control and indication circuits 2 Wayside Relay used in combination with PN 150BM for switch control 3 Car carried Relay Contacts SIC Silver to Silver Impregnated Carbon Normal and Reverse Sil Sil Silver to Silver Normal and Reverse 1 2 2 Mechanical The following mechanical specifications are common to all PP 151 relays covered in this manual Dimensions Height7 1 16 17 93 cm Width 2 7 16 6 19 cm Depth 8 3 8 21 27 cm Temperature 40 F 40 C to 185 F 85 C Indexing Refer to Section 2 3 Weight 7 0 Lbs 3 175 kg Mounting Base N341785 Wayside Old Style N437090 Car carried Old Style N451376 0302 All Above Improved Style Mounting Base Weight 17 5 oz Old Style 1 2 SM 4596G Rev 1 May 2008 A 4 AnsaldoSTS Union Switch amp Signal Mounting base Dimensions SM 4596G Rev 1 May 2008 General Information 9 5 oz Improved Style Height7 15 16 20 16 cm Width 2 7 16 _ 6 19 cm Depth 2 7 16 6 19 cm old style Depth 1 25 32 4 52 cm Improved Style 1 3 DN 4 AnsaldoSTS General Information Union Switch
25. n Torque 6 Pt Final Electrical Inspection Heel Contact Spacer SM 4596G Rev 1 May 2008 Table II 108 50 Charge 500 grams Spacer between permanent magnet ext and armature stop pins Front stop pin spacer Contact just open Back stop pin spacer Contact just open Back stop pin spacer Contact must close With opposite contacts just closed Armature against either pole piece With operating arms removed Plus lead on upper left mounting base receptacle viewed from front reverse contact must be closed Plus lead on upper right mounting base receptacle viewed from front normal contacts must be closed After charge To reverse armature After cover has been applied Permissible variation of polar Armature must go from stop pin to stop pin with 50 of charge energization Force on bottom contact engaging pin of opera sting arm to pull armature from permanent magnet after energizing only to level required to cause reversal of armature to side being tested Recheck tests 6 to 9 with cover applied 1 2 of Armature Stroke Front and Back Contacts Open 4 11 Shop Maintenance N 4 AnsaldoSTS Union Switch amp Signal Table 4 3 Table Il PP 151 Polar Relay Calibration values Relay Resistance ohms 25 240 400 400 400 4 12 Minimum Pick up and Workina Maximum Pick up and Workina 0 24 6 2 22 0 Wayside Relay Only 0 0918 0 0686 27 4 Car Carried
26. nter of the tip The physical air gap at other points of the armature tips shall not vary from the nominal value by more than plus or minus 0 002 0 015 Min 0 019 Max for nominal air gap of 0 017 Side play between the armature bushings and pivots should be 0 002 to 0 0035 End play should be held to 0 010 Min to 0 020 Max The Stop Pin shall strike the pole face as nearly flat across its surface as possible and it is permissible for light to be barely visible across 25 of the diameter of the pin on one side only The Safety Stop Pins must not touch the pole faces and with the armature assembly tightened to the relay frame the armature must not be off center more than 0 015 at either pole piece SM 4596G Rev 1 May 2008 4 5 DN 4 AnsaldoSTS Shop Maintenance Union Switch amp Signal 4 5 3 Permanent Magnet With the magnet against the pole piece and the front permanent magnet extension clamping screws loosened slightly and the back stop pin against the pole face adjust the front air gap between the armature stop pins and the permanent magnet extension to a nominal value of 0 012 shown in Table I Test 1 Neither stop pin should project over the edge of the permanent magnet extension The extension must be securely clamped and the screw heads locked with the lock washers provided The rear air gap should be adjusted to a nominal value of 0 012 in a similar manner 4 5 4 Armature Stroke The armature stroke sha
27. s in paragraph 4 2 2 of this manual 4 5 6 1 Pre adjustment Pre adjust the contacts with the contact block mounted on the relay frame if necessary but do not set them to meet calibration Best contact stability is obtained by slightly over bending the spring and returning it to the desired position 4 5 6 2 Adjustment Limits The contacts are to be adjusted to just touch when using closed spacer As a guide there should be no more than 2 grams spring pressure between the contact tips For any contact adjusted open using nominal spacers per Table No 1 a 0 005 thinner spacer for the fronts and the backs must allow the contacts to be closed Both contacts should be touching at the closed spacers it is permissible for light to be perceptible on one tip but both must be touching no tight perceptible at full stroke When the armature is held at mid stroke neither fronts nor backs touching all heel springs should rest flat against the bottom edge of the driver slot For those relays which do not meet the above condition there is a maximum clearance allowable of 0 010 between the bottom of the heel spring and driver slot Under no circumstance is the upper edge of the heel spring clip to be below the bottom of a driver slot Also no heel spring is permitted to rub against the sides of the driver The driver clip on the armature has slotted holes to allow the clip to be adjusted so that no rubbing is evident 4 5 6 3 Adjustment Proc
28. t switch Sl to Normal Relay should energize in the normal position i Reduce the de power supply output to zero set switch Sl to REVERSE and slowly increase the output until the armature reverses The value of energization at which the armature reverses should be between the MIN and MAX values given in Table 4 2 H it j Repeat steps g through i but reverse the polarities k The Normal and Reverse values should be within 12 of each other AMMETER 20 RELAY POWER VOLTMETER NORMAL REVERSE UNDER SUPPLY ee Figure 4 3 PP 151 Relay Test Circuit 4 6 4 Armature Travel When the polar reversal value is being measured the armature shall start the travel from the stop on the one side and shall continue its travel until it comes to rest on the opposite stop When the armature is slowly pulled away by hand from its last energized position but not far enough to open the contacts on that side it should return to its stop when released SM 4596G Rev 1 May 2008 4 9 y TEF AnsaldoSTS Shop Maintenance Union Switch amp Signal 4 6 5 Special Test This test applies to relays with single wound coil only Connect the relay according to the circuit shown in Figure 4 4 and apply 50 of the charge value When the energization is pole changed the armature must travel from stop pin to stop pin Repeat test on all contacts LI l y amp 0 A Figure 4 4 Circuit for Speci
29. tacts are open at least 0 050 inch and the contact stops have light perceptible approximately 0 003 inch opening 4 6 CALIBRATION 4 6 1 Recommended Test Equipment Table 4 1 Recommended Test Equipment NOMENCLATURE PART MODEL TYPE NO Power Supply 0 40 VDC HP6205B or equivalent Digital Multimeter two required HP3435A or equivalent DPDT Switch SI SPST Switch S2 4 6 2 Polarity See Figure 2 3 The polarity should be checked as follows With the positive power lead connected to the or A coil terminal the negative power lead connected to the or B coil terminal or the center tap connection of the coil and the relay energized at the charge value the lower normal contacts shall be closed 4 6 3 Procedure Connect the circuit as shown in Figure 4 3 and proceed as follows a Set ammeter to appropriate current range b Set voltmeter to appropriate voltage range 4 8 SM 4596G Rev 1 May 2008 7 AnsaldoSTS Union Switch amp Signal Shop Maintenance c Set do power supply to appropriate output range d Set switch S1 to Normal e Turn dc power supply on and close S2 f Observe ammeter and adjust do power supply output control to obtain the charge current reading indicated in the Amps portion of the Charge column in Table 4 2 Note that relay energizes and remains energized as voltage is increased g Set switch Sl to Reverse Relay should energize in the reverse position h Se
30. with technical equipment in service Please consult your local US amp S sales representative in the event of any irregularities with our product We expressly disclaim liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved US amp S spare parts are used as replacements SM 4596G Rev 1 May 2008 i N 4 AnsaldoSTS Revision History Union Switch amp Signal Revision History DATE NATURE OF REVISION aa October 1986 Initial Issue May 2008 Incorporated ECO R 1175 i SM 4596G Rev 1 May 2008 7 AnsaldoSTS Union Switch amp Signal Table of Contents Table of Contents 1 GENERAL INFORMATION ooonncccccccccnoccrnncccn rr 1 1 11 Se nae cti dd a little viele svete len es 1 1 HE Fs HR to ETT IEEE 1 1 R a lt ar le tunis dicen even eee Leela tv eee aed ets 1 1 1 2 SPECIFICATIONS TT 1 1 W201 IO Ctr Call cacon A dE vated E dd 1 1 1 22 Mechanical cw nie eta kiana ital Vitae ee atl eet ee os 1 2 2 INSTALLATION HTHH 2 1 24 MOUNTING Base ant 2 1 2 2 Relay A e lanes athe oe eet 2 1 2 3 Receptacle Contact Springs see eee eee eee eee eee eee 2 2 2 31 Old Style Base Only iii ida radar ea ara aaa 2 2 2 3 2 Improved One Piece Base Only sese eee eee eee 2 2 2 3 3 Installing Wires in Receptacle Contact SpnngS eee eee eee eee 2 4 2 3 4 Base Wiring for Wayside or Car Carried Relays sss
31. with the two mounting bolts R451299 0102 that pass through the tubes in the relay Using a torque wrench tighten the bolts to 25 5 inch pounds otherwise the operating characteristics of the relay may be changed A e KA z C A e 1 1 o i 612 2 WAYSIDE RELAY IMPROVED STYLE BASE WAYSIDE RELAY OLD STYLE BASE CAR CARRIED RELAY CAR CARRIED RELAY Figure 2 3 External Connections to Mounting Base SM 4596G Rev 1 May 2008 2 5 D se 7 AnsaldoSTS Union Switch amp Signal Installation D Y AnsaldoSTS Union Switch amp Signal 2 6 SM 4596G Rev 1 May 2008 4 AnsaldoSTS Union Switch amp Signal Field Maintenance 3 FIELD MAINTENANCE This section provides the necessary periodic preventive maintenance procedures which must be performed to ensure continuous proper and efficient operation of the PP 151 relays covered in this manual Field maintenance covers periodic inspections and performance tests 3 1 PERIODIC PERFORMANCE TEST 3 1 1 Cleaning Before inspecting and testing the relay if necessary use a soft cloth to clean the exterior to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc 3 1 2
32. y ke AnsaldoSTS 1000 technology Drive Pittsburgh PA 15219 Union Switch amp Signal 645 Be R A Se 20006 SN 4596G Magnetic Stick D C Plug In Relay PP 151 Second Generation Installation Operation Troubleshooting Copyright 2008 SM 4596G Rev 1 Union Switch amp Signal Inc May 2008 ay 4 AnsaldoSTS Union Switch amp Signal Notices Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US amp S This document has been furnished to you on the following conditions no right or license under any patents or any other proprietary right in respect of this document or its content is given or waived in supplying this document This document or its content are not to be used or treated in any manner inconsistent with the rights of US amp S or to its detriment and are not to be copied reproduced disclosed to others or disposed of except with the prior written consent of US amp S Important Notice US amp S constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible to take into account every eventuality that may arise
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