SM-4569 - Ansaldo STS
Contents
1. y AnsaldoS S 000 Technology Drive Pittsburgh PA 15219 Union Switch amp Signal _ 645 ee Le ae SM 4569 PC 250TR Vital Code Generating Relay US amp S Part No N322556 001 through 022 and N322556 818 Installation Operation Troubleshooting Copyright 2008 SM 4569 Rev 1 0 Union Switch amp Signal Inc August 2008 ay 74 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 1s 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 1s impossible to2. 3 2 2 Service Requirements 3 2 2 1 General All vital code relays must be inspected and tested at least once every two 2 years The tests and inspections are to include starting voltage proper code and on time operation 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 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 code relays be removed from service for shop repairs when the starting values and code rates are not within the limits given in Table 4 3 or the On Time values are less than 38 at minimum voltage SM 4569 Rev 1 0 August 2008 3 1 NY AnsaldoSTS Field Maintenance Union Switch amp Signal CAUTION Calibration of these relays must be made either in a test stand or on a non metallic surface When field testing with covers on do not set the relays on steel tables or house floors Relays must be supported on a non magnetic surface Never place the relay with its base contacts facing downward to do so can cause damage to the relay 3 2 2 3 Test Procedures Procedures that test the operating characteristics of the PC 250TR style relays as described in Sections 3 and 4 In thi
3. Table 4 1 Contact Cleaning Materials Cleaning Item Burnishing Tool P K Neuses Co No 3 316 pkg of 5 J397187 Burnishing Tool P K Neuses Co No N318 Heavy Duty pkg of 5 J397187 001 Paper Strip strips cut from 67 pound white Springhill Vellum Bristol Paper pkg of 50 J793094 US amp S also recommends the following commercially available cleaning items e Emery paper wet or dry 600 grit cut in strips SM 4569 Rev 1 0 August 2008 4 1 A 77 AnsaldoSTS Shop Maintenance Union Switch amp Signal e Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or Equivalent Note When using the paper strip clean the silver platinum contacts first and clean the tungsten contacts last Discard the paper strips when dirty 4 2 1 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 steps c several times 1f necessary e Using the alcohol spray give the contacts a degreasing wash f Place the paper strip between the open contacts then close the contacts and withdraw the paper strip g Repeat the previous steps several times 1f necessa
4. mo e 16 11 8 10 123205 125 125 1 9 16 1 ae war 18 181 zm e 16 11 ee 27605 28 22 4m 60 16 11 8 10 420205 44 46 5 9 e n 6 70 48205 46 50 s 60 tom 8 14 56 48 05 46 50 4 12 SM 4569 Rev 1 0 August 2008 N 74 AnsaldoSTS Union Switch amp Signal Parts Lists 5 PARTS LISTS 5 1 PC 250TR Relay Main Assembly Common parts for all PC 250TR Code Generating Relays are in the following table Refer to Figure 5 1 Table 5 1 PC 250TR Relay Generic Components Tem PartNamber Deseription Quantity 6 furrosss KNOBKNUREEDTHNUT 1EA s oase PNROLSST 1E 9 m1861 sPRNGPLATED 1EA SM 4569 Rev 1 0 August 2008 5 1 RV 4 AnsaldoSTS Parts Lists Union Switch amp Signal Tem Far Number Description Quantity CLIP MNT ON VITAL RELAYS a Not illustrated b Shock Indicator on N322556012 and N322556818 only SN VA AS EN VIO 7 8 He YA RE re l ERU ai EN 6 mene d 3 Ek i ING fe e LC y gi LX X d i Figure 5 1 PC 250TR Relay Main Assembly 5 2 SM 4569 Rev 1 0 August 2008 AN 74 AnsaldoSTS Union Switch amp Signal Parts Lists 5 2 PC 250TR Relay Specific Parts The following table tabulates
5. Signal Parts Lists 5 6 Relay Mounting Bases 5 6 1 Solderless Type Old Style Refer to Figure 5 4 Table 5 6 Relay Mounting Base Old Style item PartNo Description Quantity Cao 047501 WASHER 1 4 STEEL PLATE 4EA Plastic Bags item 34 are thermosealed shipped with the mounting base and contain the following e Required quantity of contact receptacles J680165 e 2 Tags J075828 e 2 4 x 3 16 round head Z type self tapping screws J052674 e 4 4 20 X 4 round head steel machine screws J052667 e 4 steel lock washers J047775 e 4 steel plate washers J047501 e 4 4 30 steel hex nuts J048002 e Instruction sheet US7 Sh 1184 10939 SM 4569 Rev 1 0 August 2008 5 9 Q 74 AnsaldoSTS Parts Lists Union Switch amp Signal 4 15 16 19 32 2 1 2 1 27 23 IIEIIII IEIZEIIII 2 1 2 E 19 32 3 3 4 FRONT OF BASE Figure 5 4 Relay Mounting Base Old Style 5 10 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal Parts Lists 5 6 2 Solderless Type New Style Table 5 7 Relay Mounting Base New Style Tem PartNo Description Quantity 6 15001960120 SCR SST 114 2014 4EA 8 34751200112 WASHERSSTPLATE NO14 4EA o 0210108 NUT A 0SSTHEX 4EA Plastic Bags item 11 are thermosealed shipped with the mounting base and contain the following e Required quantity of contact receptacles J680195
6. Silver Platinum contacts B high voltage Tungsten contacts SM 4569 Rev 1 0 August 2008 5 5 74 AnsaldoSTS Parts Lists Union Switch amp Signal E zm i tk 5 062 MIN 062 MIN 062 MIN 062 MIN ipe AND OR 32 22 X X2 MSS 005 MIN 015 MAX o 2 TOTAL END PLAY 22 43 44 5 3 0 020 MIN m id ji WT eB wa Nes Tea D Y 1d ipi i ge d TS zi 180 amp 270 CODER Figure 5 2 PC 250TR Relay Operating Unit Assembly Sheet 1 5 6 SM 4569 Rev 1 0 August 2008 RN 77 AnsaldoSTS Union Switch amp Signal Parts Lists 22 2 RU K iy ET LMS We E 4 D LiL i d n 3 E 8 a 120 o 50 amp 75 CODER Figure 5 3 PC 250TR Relay Operating Unit Assembly Sheet 2 SM 4569 Rev 1 0 August 2008 5 7 A 74 AnsaldoSTS Parts Lists Union Switch amp Signal 5 5 Relay Operating Unit Pendulum and Contact Spring Support The following table correlates the contact spring material and illustration views for the Pendulum and Contact Spring Support assemblies associated with the PC 250TR Relay Operating Units Table 5 5 Pendulum and Contact Spring Supports Part No Code Panno Code LIE Note L V low voltage Silver Platinum contacts Contact Spring Part No R377144 H V high voltage Tungsten contacts Contact Spring Part No R380690 5 8 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp
7. Switch amp Signal 4 3 REPAIRS AND REPLACEMENT Since the contacts are the major wearing parts in this relay in most cases the relay can be restored to proper operation by dressing and readjusting them 4 3 1 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the parts lists in Section 5 for part information and location of parts In general to dismantle the plug in relay perform the following sequence a Remove relay cover seal b Carefully remove plastic cover c Remove the operating unit as required d Remove contact assembly as required e Remove contacts contact springs as required f Disassemble the operating unit as required 4 3 2 Reassembly Reassembly is accomplished generally in the reverse order of disassembly The following subsections provide additional instructions to be followed during reassembly of this relay When reassembling the code transmitter relay do not over tighten screws or nuts and do not apply force that may cause damage to parts 4 3 2 1 Contact Replacement Shop repairs should consist of replacing badly worn or burned contacts and correcting any condition that might contribute to improper relay operation Each contact spring and contact post is separate and with care can be replaced without affecting the other contacts Proper care should be exercised when contacts are replaced to make certain that the hinge spring supports are not forced out of li
8. dn Vl a nu sac RR Re Do 4 5 GO 4 5 gA ro MEVS EC TTE 4 6 A EL NEL Golgi ei EE D TT OUT RU 4 6 44 5 GontdcE ReSISIal6 Bacon end oa a nan uvas cane in ant 4 7 S SENE UMS 2 LN MN ee ee eer eee 4 8 4 5 1 Recommended Equipment iii 4 8 49 2 Procedu mc ES 4 8 4 6 CALIBRATION REQUIREMENTS aaan a aaa eene en ne 4 12 HO la In eV Te 4 12 DerGonlackResistance asa an arian ens aua Saad S t aded nates 4 12 b PARTS IST 5 1 5 1 JO 250TR Relay Main ASSGmbly 2355 mra uitium bx nn ee ed Ded ena eed Dee 5 1 5 2 PC 250TR Relay Specific Parts pe 5 3 9 9 PC 250TR Relay Operating Units ss sense sc t etum a ai 5 4 5 4 PC 250TR Relay Operating Unit Specific Parts nnnnnnnnnennnnennnnnnnnnnsnnnnsnnrnnnnrrrsrnrrnsnrrrerrenn 5 5 5 5 Relay Operating Unit Pendulum and Contact Spring Support 5 8 0 6 Relay Mounting BASES se TET 5 9 5 6 1 Solderless Type Old Style reris e b In rite ota steadied neta i heeds deeds 5 9 5 6 2 Solderless Type New Style sn 5 11 6 RAIL TEAM AND TECHNICAL SUPPORT ee 6 1 iV SM 4568 Rev 1 0 August 2008 77 AnsaldoSTS Union Switch amp Signal Table of Contents Figure 2 1 Figure 2 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Table 1 1 Table 1 2 Table 2 1 Table 4 1 Table 4 2 Table 4 3 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Tab
9. for 18 20 wire J6801950002 for 10 12 wire e Contact springs item 4 e Tags item 5 screws lock washers plate washers and nuts items 6 7 8 and 9 The following items are also supplied mounting base instructions sheet item 10 coil connection diagram and conversion chart SM 4569 Rev 1 0 August 2008 5 11 AM 77 AnsaldoSTS Parts Lists Union Switch amp Signal LOCKING SIDE OF STRIKE VIEW A SHOWING MTG OF STRIKE 4 15 16 127 32 19 32 2 1 2 E A CS NZ EE fo r E ES Ea a Py by ES ES Ed Ed 3 U LOCKING SIDE i RECEPTACLE SPRINGS LOCKING SIDE DOWN OF STRI KE N438689 003 2 uw e 5 N Y 19 32 5 16 4M1 0004 00 3 3 4 Figure 5 5 Relay Mounting Base New Style 9 12 SM 4569 Rev 1 0 August 2008 NY EE n 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 4569 Rev 1 0 August 2008 6 1 77 AnsaldoSTS RAIL Team and Technical Support Union Switch amp Signal A e AnsaldoSIS Union Switch amp Signal End of Manual 6 2 SM 4569 Rev 1
10. the pendulum should continue to oscillate with appreciable amplitude for a minimum of ten complete cycles 4 4 4 Contacts With the relay in a level position and with the pendulum free to operate adjust the contacts as follows a Atthe start of the adjustment all contacts should be moved out of engagement The pendulum must hang free and be practically vertical Pendulum position should be checked any time that tuning weights are added or arranged b Adjust initial pressure of all contacts against their stops from 4 to 6 grams measured at the contact tips c When the relay is viewed from the top with the handle toward the observer the contacts are as shown in Figure 4 4 d With all contacts open set power contacts to 0 010 opening With front power contacts open 0 036 0 003 set drive contact on same side to just make With back power contacts open 0 036 0 003 set drive contact on same side to just make 4 6 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 4 5 Contact Resistance The resistance of each set of contacts should he measured with the pendulum held in such a position that the contact compression is approximately 0 010 Resistance should not exceed 0 05 ohm for silver platinum contacts 0 5 ohm for tungsten Lx peso i m DRIVE oe JC Figure 4 4 Front of Relay Top View SM 4569 Rev 1 0 August 2008 4 7 NY i B AnsaldoSTS S
11. the components that are specific to different PC 250TR Relay part numbers Table 5 2 PC 250TR Relay Specific Components Relay Operating Unit mm T Resistor N322556 Item 12 e Item 34 00 norme 501 ane 510 002 510 003 300 004 510 005 510 300 007 510 008 510 300 010 on 012 0 0 0 0 0 0 0 0 als 8 013 N433751 5313 J271169 510 014 N433752 5614 J720815 68 8 016 510 016 dr 017 018 216 219 30 026 510 02 510 022 N433755 002 300 For components specific to each Operating Unit Item 12 refer to Table 5 3 and Table 5 4 SM 4569 Rev 1 0 August 2008 5 3 A 74 AnsaldoSTS Parts Lists Union Switch amp Signal 5 3 PC 250TR Relay Operating Units Common parts for all PC 250TR Code Generating Relay Operating Units are tabulated in the following table Refer to Figure 5 2 and Figure 5 3 Table 5 3 PC 250TR Relay Operating Unit Generic Components tem Part Number Description Quantity 6 4522150 SCREW 8 32X6 8 FIL HD STEEL 6EA 8 marees STORFRONT 1EA Co ere MAGCORE 1EA 20 J071963 L V POST TERMINAL ere Table 5 4 SCR 8 32X7 16 FILLISTERSS 32 J071962 H V POST TERM TUNG CONT Refer to Table 5 4 5 4 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal Parts Lists 5 4 PC 250TR Relay Operating Unit Specific Parts The following table tabulates the components that are specific to different PC 25
12. 0 August 2008
13. 0TR Relay Operating Unit part numbers Table 5 4 PC 250TR Relay Operating Unit Specific Components Pendulum amp pole Piece Coil Contact Posts Operating Unit Contact Spring Item 10 ere Items 20 and or 32 ai ar 28 sr s 9 rnaveaes Na7TA64 M377127 N378745 60 NA A A A 180 rnaveae7 arre M377127 N378745 60 na a A A A 75 N380644 Nseoai Msrrizr N378745 60 2 8 8 A A N380645 N3062 M377127 N378745 60 2 8 8 af A 75 Naso646 Nseocas M377127 N378746 40 2 8 8 af A 120 Nae3779 Naexrz uen N378745 60 4 8 8 e 160 Nass 80 fasses M377127 N378745 60 4 8 8 B 8 75 Nso5164 N3osz Mse6425 N378746 40 4 8 8 B B 270 rnaesas1 N3osso M377127 N378746 40 4 8 8 B B 120 Na33750 sexe M377127 N433749 oo 4 8 8 B 8 75 rnasa7e1 Nsoss Msrrimr N378745 60 4 8 8 e e 120 Na33752 Nsesr uerner N433749 90 4 8 8 e e 180 Na33753 Nsesr uosss N378745 60 4 8 8 B B 270 Na33755 Nass uosss N378745 60 4 e B B B 420 rnaas7o2 asso Msrriz sas 90 4 8 8 B 8 90 NA37107 Narraes M377127 wagsrto oo NA A A 75 Na37792 Nasrrs uses N378746 40 2 8 B A 270 Na33755001 N433768 001 M386425 N378745 60 2 B B A A 420 Na35702001 N435703 001 M377127 N378745 60 NA A A S0 Note A low voltage
14. 20 510 510 300 510 510 300 510 10 1042 40 1 Internal arc suppression resistor in series with coil 1 2 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal General Information 1 3 2 Mechanical The following mechanical specifications are common to all PC 250TR relays addressed in this manual Table 1 2 Relay Mechanical Specifications Dimensions Height 7 1 16 17 93 cm Width 41516 I284om Deph 83 gizom 40 F 40 C to 185 F 85 C Determined by Relay Part Number see Subsection 2 3 Weight 63415 ounensions Width 4 15 16 12 54 cm Depth 2 7 16 6 19 cm Old Style Base Depth 1 25 3 2 4 5 cm New Style Base 1 4 SAFETY SUMMARY Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to CAUTION and WARNING These headings may appear throughout this manual Caution statements indicate conditions that could cause damage to equipment Warning statements indicate conditions that could cause physical harm serious injury or loss of life Always observe standard precautions familiar to trained electrical technicians Always adhere to all safety regulations stipulated by your administrative procedures SM 4569 Rev 1 0 August 2008 1 3 77 AnsaldoSTS General Information Union Switch amp Signal AN 74 AnsaldoSTS Union S
15. Maintenance Union Switch amp Signal 4 6 CALIBRATION REQUIREMENTS 4 6 1 In Service Test Calibration requirements will be met when the relay adjustment values are the same as those given in Table 4 3 of this manual After any shop adjustments are made repeat the calibration procedures in Section 4 5 2 If the values are not within the tolerance given in Table 4 3 the relay should not be placed in service 4 6 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 resistances should not exceed the following values e Silver Platinum contacts 0 05 2 maximum e Tungsten contacts 0 5 Q maximum Contact surfaces should not be disturbed unless there 1s evidence of severe pitting from excessive loading or an accidental short through the contacts When contacts must be dressed 600 grit emery paper should be used and should be followed by the use of the burnishing tool and paper strip Table 4 3 PC 250TR Calibration Values Fr n T O Rated Rated Rated Max At Rated At Min At Max 75 o om 8 4 7 7205 74 7 wo 4 ty 8 14 75 123405 15 121 1 60 ty 8 14 6 ser 18 18 zm 4 tora 8 14 6 276205 28 27 4m 40 tora 8 14 633 420405 44 46 7 9 1 n 1 67 72 05 74 70
16. UA ORA LOCK SIDE mu LOCK SIDE OLD MOUNTING BASE NEW MOUNTING BASE Figure 2 2 Receptacle Contact Spring Installed 2 4 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 Table 2 1 Contact Spring Crimping Tools Improved Base Crimping Tool agai NAS DES Receptacle Pang Contact Spring J397138 10 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Standard M451142 2702 J397188 18 20 AWG 680179 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 proper 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 2 4 SM 4569 Rev 1 0 August 2008 ay 77 AnsaldoSTS Union Switch amp Signal Installation 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
17. and Contact Spring Supports LR 5 8 Relay Mounting Base Old Style nt 5 9 Relay Mounting Base New Style 5 11 SM 4569 Rev 1 0 August 2008 V AM 77 AnsaldoSTS Table of Contents Union Switch amp Signal A 4 AnsaldoSIS Union Switch amp Signal vi SM 4569 Rev 1 0 August 2008 RN 4 AnsaldoSTS Union Switch amp Signal General Information 1 GENERAL INFORMATION 1 1 INTRODUCTION This manual provides service information for the PC 250TR Plug In Code Transmitter Relay The PC 250TR relay is a code generating relay for coded track circuits and cab signaling equipment This relay 1s DC operated at a specific frequency to open or close a circuit at the set rate providing equal off and on times The design of the PC 250TR relay conforms to all applicable AREMA specifications 1 2 DESCRIPTION 1 2 1 General The PC 250TR relay 1s manufactured with various combinations of low voltage L V silver platinum and high voltage H V tungsten contacts The PC 250TR relay 1s available in a range of operating frequencies 50 75 120 180 270 and 420 cycles per minute The relay 1s factory calibrated to operate across a wide environmental range All moving parts are enclosed in a sturdy transparent dust and moisture resistant cover Indexing pins in the relay ensure installing in the proper base Relays lock securely in the plug in position 1 2 2 Coils Coil resistances of PC 250TR relays are depending on part numbe
18. ed with indexing pins to prevent insertion of an incorrect relay into a mounting base Each relay 1s accompanied by an indexing plate that 1s applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with corresponding indexing plate 1s shown in Figure 2 1 WARNING Do not drill new holes in a base indexing plate that will permit application of relays with different part numbers or change indexing pins on the back of a relay unless it 1s being converted to a new part number These actions create a hazard that may compromise safety circuit functions The following data defines the indexing that has been established for relays covered by this manual a The index code always consists of four digits 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 nameplate attached to the front of the relay The first two digits of the index code are the last two 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 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 1s determined by the placement of the holes in the n
19. hop Maintenance Union Switch amp Signal 4 5 CALIBRATION CAUTION Calibration of these relays must be made either in a test stand or on a nonmetallic surface When field testing with covers on do not set the relays on steel tables or house floors Relays must be supported on a non magnetic surface 4 5 1 Recommended Equipment The following table specifies the equipment recommended for use to calibrate the relays Table 4 2 Calibration Equipment Cycle Counter Redington Counter R9 3206 or equivalent Stopwatch Accurate within 0 1 sec On Time Meter PD 30 J620754 or equivalent 4 5 2 Procedures A rear view of the relay base or mounting base showing the terminal arrangement is shown in Figure 4 5 a Starting Voltage Check 1 Connect the code transmitter into the test circuit as shown in Figure 4 6 2 With the contacts adjusted pole pieces set and the pendulum at rest slowly increase the power supply output until the pendulum begins to oscillate The voltage at this point should not exceed the maximum starting voltage given in Table 4 3 b Code Rate Check 1 Connect the code transmitter test circuit as shown in Figure 4 6 4 8 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal Shop Maintenance 2 Ensure that the code transmitter 1s operated at the rated voltages given in Table 4 3 3 Setthe power supply at nominal rated voltage and allow relay to operate for approximately
20. l complement of receptacle contact springs M451142 2702 to accommodate one or two 14 16 wires mounting fasteners and tags It can be equipped with receptacle contact springs for one or two 10 12 wires M451142 2703 or for one or two 18 20 M451142 2701 wires Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with installation Each solderless receptacle contact spring should be inspected for physical damage before proceeding with installation The following is recommended when installing solderless receptacle contact springs a Receptacle contact springs must be inserted into the base with the lock side down lanced tab up 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 might not provide the required contact pressure after the relay is inserted If the lanced tab does not touch pull it up slightly using fingers or a suitable tool c c After insertion pull firmly on the wire to make certain the receptacle contact spring 1s locked in the cavity SM 4569 Rev 1 0 August 2008 2 3 NY 4 q 4 AnsaldoSTS Installation Union Switch amp Signal I l l i RECEPTACLE RECEPTACLE SPRING SPRING mtl ctl LANCED DEL LANCED PE 1 TAB TAB
21. le 5 6 Table 5 7 List of Figures Typical Plug n Relay and Mounting Base 2 1 Receptacle Contact Spring Installed 2 4 Shock ndicator Eo rer 1 0 p a em en ton Nie eRe 4 3 Position of Armature to Pole PICCE Sa a tata ade 4 5 SIDE All Gap sae eee a A 4 6 Front of Relay Top View pp 4 7 Mounting Base Termilidls sis deeem ide totes eda a a a S 4 9 Code Transmitter Code Rate Test Circuit 4 9 Code Transmitter On Time test Circuit 00nnnaannnnennnnsnnnneenrnrsrrnrnrnrrrsrrrsrnrresrrrrsrnrrennne 4 11 PC 250TR Relay Main Assembly sn 0 2 PC 250TR Relay Operating Unit Assembly Sheet 1 4 5 6 PC 250TR Relay Operating Unit Assembly Sheet 2 et 5 7 Relay Mounting Base Old Style susie ed Une bed d cd vase uode mde kp eats 5 10 Relay Mounting Base New Style nnnn0nnnnnannnnnnnnenrnnnnsrrnerrrnsrrnesrnrnnsnrrrsrnrensnrrrsrnrnne 5 12 List of Tables Relay Electrical Specifications nt 1 2 Relay Mechanical Specifications LL 1 3 Contact Spring Crimping ToolS n saennnnaaannennnnsennennrnnsnrrrnrnrnnsrnrrnsnrrnrnrensnnrsrnrenenrrennnnen 2 4 Contact Cleaning Matenas sn ee rs into 4 1 Gallbrauom Eonen ts a en ne ee nc ee 4 8 PC 250TR Calibration ValueS ss 4 12 PC 250TR Relay Generic Components sn 5 1 PC 250TR Relay Specific Components ss 5 3 PC 250TR Relay Operating Unit Generic Components pp 5 4 PC 250TR Relay Operating Unit Specific Components pp 5 5 Pendulum
22. ne sufficiently to cause a set which would throw the other contacts out of line or render the hinges susceptible to breakage Contacts that are not to be replaced may be dressed if necessary by following the procedures in section 4 2 1 4 4 SM 4569 Rev 1 0 August 2008 RN 4 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 4 ADJUSTMENTS 4 4 1 Recommended Tools The tools recommended for relay adjustment are e Gram Scale 0 10 grams e Gap Gauge 0 001 0 80 4 4 2 Starting Air Gap In making all mechanical and contact adjustments the relay must be mounted in a level position The armature position with respect to the pole pieces when viewed from the front of the relay should be adjusted to the limits shown in Figure 4 2 by shifting the pole pieces slightly or rearranging the tuning weights on the armature or on 180 coders the pendulum arm may be bent slightly if necessary POLE PIECE ARMATURE RM 3 a 16 TO 16 Figure 4 2 Position of Armature to Pole Piece SM 4569 Rev 1 0 August 2008 4 5 N qM E 4 AnsaldoSTS Shop Maintenance Union Switch amp Signal 4 4 3 Side Air Gaps The armature should be centered between the pole pieces with a minimum clearance of 1 16 1 64 from either pole piece when moved to a position between the poles refer to Figure 4 3 p a i Figure 4 3 Side Air Gap When the armature is pulled back to approximately the full stroke position and then released
23. one minute before continuing with the next step 4 Set switch SI to OFF and ensure that the counter is reset to zero 5 Using a stopwatch to make the time measurement simultaneously set switch S1 to ON and start the stopwatch 6 Setswitch SI to OFF when the stopwatch indicates that exactly three minutes have elapsed 7 Divide the reading on the counter by three and observe that the result 1s within the appropriate code rate indicated 1n Table 4 3 4H 3H 2H 1H Sj E J ca 4B 3F eB 1 D Figure 4 5 Mounting Base Terminals OFF 1 H F had e ON HEEL M1 CODE TR v TR COUNTER Figure 4 6 Code Transmitter Code Rate Test Circuit SM 4569 Rev 1 0 August 2008 4 9 8 NY x 4 AnsaldoSTS Shop Maintenance Union Switch amp Signal Note The code speed is adjusted to the value given in Table 4 3 by varying the number and size of tuning weights as required To increase code frequency on 50 and 75 coders add weight to the pendulum To increase code frequency on the 120 180 270 and 420 coders remove weight from the pendulum Repeat Steps 4 through 7 at the rated maximum and minimum voltages The code rates should be within the limits specified in Table 4 3 Note The amplitude of the pendulum should be checked at the rated maximum voltage given in Table 4 3 The amplitude should not be so great that the pendulum strikes any fixed part of the transmitte
24. r c On Time Check Connect the code transmitter test circuit shown in Figure 4 7 and proceed as follows l With PD 30 connected between a set of heel and front contacts set the PD 30 function switch to SET 100 and adjust the ADJ control for an indication of 100 on the meter Set the PD 30 function switch to SLOW and observe the movement of the meter pointer Take the reading after the pointer settles to a somewhat steady indication After final tuning the on time must be 42 minimum to 48 maximum 46 52 for 50 code only for both front and back contacts at both minimum and maximum voltages To check the on time period of the back contact of the CT repeat steps 1 and 2 with the PD 30 connected between the heel and back contacts Repeat steps 1 through 3 for all sets of coding contacts SM 4569 Rev 1 0 August 2008 ay 74 AnsaldoSTS Union Switch amp Signal Shop Maintenance Note In the event that on time of any contact at rated minimum voltage is below 42 46 for 50 code only the contact adjustment shall be carefully checked and changed as necessary observing the limits specified At rated maximum voltage the on time of both left and right contacts should be approximately the same ON TIME METER M1 VOLTAGE CODE TR MONITOR UNDER TEST Figure 4 7 Code Transmitter On Time test Circuit SM 4569 Rev 1 0 August 2008 4 11 N 74 AnsaldoSTS Shop
25. r 40 60 and 90 ohms Refer to Section 1 3 1 to correlate part numbers to coil resistance values The resistance selected depends on the system voltage and circuitry 1 2 3 Contacts Contacts of the PC 250TR relays are low voltage L V and high voltage H V L V contacts are marked with green contact posts and are for use in circuits below 50 volts L V contacts are silver platinum to silver platinum contact posts H V contacts are for use in circuits above 50 volts to provide longer contact life however they cannot be used in low voltage circuits due to the contact resistance that they develop SM 4569 Rev 1 0 August 2008 1 1 ay 74 AnsaldoSTS General Information Union Switch amp Signal 1 3 SPECIFICATIONS The following subsections provide the electrical and mechanical specifications of the code transmitter relays covered in this manual 1 3 1 Electrical Relay electrical specifications are tabulated below Table 1 1 Relay Electrical Specifications US amp S Cycle Contact Arrangement che Arc Supr Part No Minute 1 F 2 B 3 F 4 B Q Res 1 Na22556001 180 Lv LV LV Lv 1012 Nax656002 75 LV LV LV Lv 1012 60 Naz556004 160 Hv Hv LV Lv 10 2 0 ruazass6 005 75 Hv av LV Lv 1012 60 Na22556 007 180 Hv Hv Hv Hv 10 2 60 Naz65600 75 HV Rv Hv Hv 10 12 0 5 v mv Le 90 ee0 Pav 1 60 90
26. ry 4 2 1 2 Contacts With Heavy Tarnish Slightly Rough or Pitted Perform the procedure in Subsection 4 2 2 1 steps b to g 4 2 1 3 Contacts with Surface Film or Oxidation Not Pitted Perform the procedure in Subsection 4 2 2 1 steps f and g 4 2 SM 4569 Rev 1 0 August 2008 77 AnsaldoSTS Union Switch amp Signal Shop Maintenance 4 2 2 Shock Indicator WARNING Any relay displaying Shock Indicator activation requires shop service before placing relay into service Failure to assure proper function of this relay may result in severe personal injury or death Relays N322556 012 and N322556 818 only have integral shock indicators The shock indicator 76801670012 displays red when the relay has been subjected to shock in excess of a safe level 1 e dropped during shipment or transport This is an indication that the relay may have mechanical damage and may not meet electrical specifications Refer to Figure 4 1 for shock indicator location on the relays An affected relay should be opened and visually inspected for damage e g kinked springs Mechanical settings should be checked and verified and the relay recalibrated and tested according to specifications by a qualified individual OO SHOCK INDICATOR IN THIS AREA un Ke 4 25 32 Figure 4 1 Shock Indicator Location SM 4569 Rev 1 0 August 2008 4 3 A AnsaldoSTS Shop Maintenance Union
27. s manual 3 2 SM 4569 Rev 1 0 August 2008 N 74 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 PC 250TR style 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 CAUTION A code transmitter must never be placed with its base contacts facing downward To do so can cause damage to the relay 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 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 obvious physical damage Remove the cover and proceed with relay contact cleaning using the following recommended cleaning materials 4 2 1 Cleaning Relay Contacts A Relay Contact Cleaning Kit part no X451646 0901 1s available and contains the following three items which may also be ordered individually
28. t ts Cen Det ER 1 3 2 INSTALLATION Sn entente idis Bocas o LLL e cube 2 1 2 2 1 2 2 MOUNTING BASE i ette etes dpi nes dentistes eee een 2 2 23 2E d i z il cH a E A E a 2 2 24 RECEPTACLE CONTACT SPRINGS te en en Pd dee tee e E EN Eust TU Eon rcd 2 3 24515 Old Stile Base Only a i tee eee qni dta ne Me ini de 2 3 2 4 2 Improved One Piece Base Only iii 2 3 2 4 3 Installing Wires in Receptacle Contact Springs 2 4 2 9 RELAY INSERTION d 2 5 3 JFIEED MAINTENANBGE ma sos oe A tpe caet Ne oid api dos Eu oes tact eee oat dos ea icecotiud 3 1 Sole INTRODUCTION se on oe de on nn ni ee a 3 1 3 2 PERIODIC PERFORMANCE TES ne en on ne ere 3 1 Sa 3 1 9 22 Service ReQUIF MIONES a5 oae A Deae xu tameo ates ue east ave aes tage ed nentur 3 1 4 SHOP MAINTENANCE 5 ni aaa bo aio tne enu Aaa bua dos ue uo tata 4 1 43 INTRODUCTION ea iba a el ew ma er tente een Dp ems 4 1 42 CLEANING AND INSPECTION pp 4 1 SM 4569 Rev 1 0 August 2008 lii NY z Table of Contents Ans mes 4 2 1 Cleaning Relay Contacts sise 4 1 2 2 2 9Bock Indie atouts dE bs M boni a RSR iot boe eiu dite 4 3 4 3 REPAIRS AND REPLACEMENT Sm aaa Ron d ED Moet heat Meenas ue Doe Snc uc 4 4 A TOS A DIS AS SOMO IN ss sarees aise I UL E I EL T II 4 4 49 2 icio oa aceite diac awnadinata invariance weaver 4 4 d DOT NE NT aei i enu E etu IE Ee et Ime MEE ME 4 5 AAA Recommended ToGo aan Ri D tenancies Gu
29. take into account every eventuality that may arise 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 4569 Rev 1 0 August 2008 Revision History NY 74 AnsaldoSTS Union Switch amp Signal Revision History DATE NATURE OF REVISION January 1994 Reissue to provide new and corrected data Reformatted and reissues to provide na dre new and corrected data Reformatted into current Service Manual template Revised to 1 0 August 2008 incorporate changes required by ECOs EE 1078 4 99 EE 1435 7 01 and EE 1570 5 02 SM 4569 Rev 1 0 August 2008 77 AnsaldoSTS Union Switch amp Signal Table of Contents Table of Contents T GENERAL INFORMATO N nn nn cn a aaa aaa a aa ne tete tete nn nt a lauren ion iaaa ai 1 1 tT INTRODUC TION merour ae ee A E 1 1 1 2 DESCRIPTION cdi ict etit Ln eie bate mes A 1 1 1 2 1 G n ral t TROC OT 1 1 Mi Gro ete LECCE 1 1 USES Oe E M ect 1 1 1 9 SPEGIFIGATIONS seo cs atte tia ate tnt e ete eaten te El ile ou ei 1 2 SEMI ied RTI EU ML 1 2 119 2 eie RU ne 1 3 TA SAFETY SUMMAR octets iren
30. 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 5 RELAY INSERTION Orient the relay to the mounting base with the nameplate right side up 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 SM 4569 Rev 1 0 August 2008 2 5 AM 77 AnsaldoSTS Installation Union Switch amp Signal AN 74 AnsaldoSIS Union Switch amp Signal 2 6 SM 4569 Rev 1 0 August 2008 RN 77 AnsaldoSTS Union Switch amp Signal Field Maintenance 3 FIELD MAINTENANCE 3 1 INTRODUCTION This section provides the necessary periodic preventive maintenance procedures that must be performed to ensure continuous proper and efficient operation of the PC 250TR style relays covered in this manual Field maintenance covers periodic inspections and performance tests 3 2 PERIODIC PERFORMANCE TEST 3 2 1 Cleaning Before inspecting and testing the relay 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 from the cover
31. umbered vertical rows of the large white nylon indexing plate which 1s 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 that comes in a bag tied to the handle of all new relays unless it is needed for replacement of a damaged indexing plate or for application to a new mounting base Never drill new holes in an existing indexing plate for then it would accommodate two or more relays of different part numbers The same applies to the positions 2 2 SM 4569 Rev 1 0 August 2008 74 AnsaldoSTS Union Switch amp Signal Installation of the indexing pins in the back of the relay unless it is being converted to another part number 2 4 RECEPTACLE CONTACT SPRINGS 2 4 1 Old Style Base Only Normally the N378609 mounting base will be equipped with the required quantity of J680165 solderless receptacle contact springs and will accommodate one or two 14 16 wires However it can 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 4 2 Improved One Piece Base Only The new one piece mounting base with hardware includes a ful
32. witch amp Signal 1 4 SM 4569 Rev 1 0 August 2008 N 4 AnsaldoSTS Union Switch amp Signal Installation 2 INSTALLATION 2 1 GENERAL Relays plug directly into a mounting base that 1s secured to a rack The only installation instructions required are for the mounting base The PC 250TR relay must be mounted horizontally and separated by at least five 5 inches from the code following relays However PC 250TR relays can be mounted adjacent to each other Figure 2 1 Typical Plug n Relay and Mounting Base It is very important that these relays be handled carefully so that no undue stresses are applied to the contact bar hinge structure which might throw the contacts out of adjustment or impair the life of the hinge spring A shipping screw which firmly holds the armature 1s applied to the relay when it leaves the factory The screw should be removed when the relay 1s placed in service and retained for subsequent use in case it later becomes necessary to transport the relay from place to place SM 4569 Rev 1 0 August 2008 2 1 NY p AnsaldoSTS Installation Union Switch amp Signal 2 2 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 contact receptacles Mounting base details are illustrated in Section 5 6 Relay Mounting Bases 2 3 RELAY INDEXING Relays are factory equipp
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