SM-4596 - Ansaldo STS
Contents
1. o o ooooooomoooo 4 13 4 5 5 Hold DoWn BOree ia e retro et a e a red exe danas d 4 14 4 5 6 Contact Openings dace areae e iow SR RO S Ch A eked ca a de 4 14 SM 4596 09 00 i TABLE OF CONTENTS UNION SWITCH 8 SIGNAL Table of Contents Section Subject Page No 4 6 1 Recommended Test Equipment Va 4 14 4 6 2 Proc dure ht le PPP ea eee eA eed nea edocs 4 15 4 7 CALIBRATION REQUIREMENTS 0200 e eee eee esee 4 16 4 7 1 In Service lest isizsizrititknisbobensnsnjnnsrntjssnsssonieliiies 4 16 4 7 2 Contact RESISTENTE suo sac aie pilates asl B gush DN gan ta 4 16 Appendix A Parts Lists and Drawings cece cece cere eee cece nnn A 1 A 1 Parts list for PN 150B Relav with Individual Contact Drivers A 1 A 2 Parts List for OId Stvle Mounting Base for PN 150B Relavs A 4 A 3 Parts List for PN 150B Relav with One Piece Molded Driver A 6 A 4 Parts List for Improved Mounting Base PN 150B Relays A 9 LIST OF FIGURES 2 1 Typical Plug In Relay and Mounting Base 20 00005 2 3 2 2 Receptacle Spring Installed 6 2 3 4 1 Relay Parts Location 0 0 cece cece tence eee 4 4 4 2 PNSISUBIOR Clay ada a ice a aos 4 5 4 3 Assembly of Permanent Magnet and Adjustment of Armature Position Indica arras yes oft ant acd A alba e TES f suet paa S 4 10 4 4 PN 150B Relay Test Circuit 0 0 2 ec eee 4 16 A 1 PN 150B Relays with Individual Contact Drivers 00002. A RELAY UNLESS IT IS BEING CONVERTED TO A NEW PART NUMBER OTHERWISE A HAZARD WILL BE CREATED THAT MAY COMPROMISE SAFETY CIRCUIT FUNCTIONS 2 4 RECEPTACLE CONTACT SPRINGS 2 4 1 Old Style Base Only The mounting base will normally be equipped with the required quantity of J680165 solderless recepta cle contact springs and will accommodate one or two 14 or 16 wires It can however be equipped with receptacle contact springs for one or two 10 or 12 wires J680181 or for one or two 18 or 20 wires 7680179 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 one piece mounting base with hardware N451376 0302 includes a full complement of receptacle contact springs M451142 2702 to accommodate one or two 414 716 wires mounting fasteners and tags However it may be equipped with receptacle contact springs for one or two 718 220 wires M451142 2701 or for one or two 10 212 M451142 2703 wires Each solderless receptacle contact spring should be inspected for physical damage and straightness before proceeding with installation The following is recommended when installing solderless receptacle contact springs a Receptacle contact springs must be inserted into the base cavity with the lock side down See Figure 2 2 b Make certain that the lanced tab is slightly compressed when the receptacle contact sp
3. Examine the area of the hinge spring and safety stop for particles and clean when required NOTE This area is difficult to inspect Backlighting the area will help consider ably 4 2 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 5 Use the compressed air to blow out all relay surfaces CAUTION DO NOT AIM THE AIRFLOW DIRECTLY ONTO THE CONTACT SPRINGS AS THEY CAN BE DAMAGED OR MISALIGNED 6 Use the compressed air to blow out the inside of the cover If the air pressure does not suffi ciently clean the cover wipe the inside of the cover with a clean lint free cloth 7 After cleaning is complete perform the armature stop pin conditioning Section 4 2 2 The relay surfaces should be blown out with compressed air to remove any stray graphite particles following the stop pin conditioning procedure 8 When the relay is completely cleaned and inspected the cover may be replaced and the seal and sealing wire installed CAUTION THE SEALING WIRE MAY BE MAGNETIC WHEN THE WIRE IS CUT AFTER THE SEALS HAVE BEEN APPLIED THE CUT OFF PIECES CAN BE ATTRACTED TO THE PERMANENT MAGNETS OF ADJACENT RELAYS OR CAN FALL ONTO THE WORK SUR FACE KEEP ALL ADJACENT RELAYS COVERED AT ALL TIMES AND CLEAN UP THE CUT OFF PIECES GOOD HOUSEKEEPING PRINCIPLES APPLY AT ALL TIMES ALSO CARE MUST BE TAKEN THAT METALLIC PARTICLES ARE NOT ACCIDENTALLY CARRIED TO THE RELAY ON HAND TOOLS THAT HAVE BECOME MAGNETIZED IF THESE PROCED
4. a Using a 600 grit emery paper strip folded with the grit side out so that both contacts can be bur nished 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 strip d Repeat step c several times if 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 strip g Repeat step f several times if necessary 4 6 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 4 2 3 2 Contacts With Heavy Tarnish Slightly Rough or Pitted a Perform the procedure in Subsection 4 2 2 1 Steps b to g 4 2 3 3 Contacts With Surface Film or Oxidation Not Pitted a Perform the procedure in Subsection 4 2 2 1 Steps f and g 4 3 CHECK OUT PROCEDURE PERFORMANCE TEST Perform calibration in accordance with Section 4 6 4 4 REPAIRS AND REPLACEMENT NOTE PN 150B relays manufactured after April 1976 have been made using glass cloth epoxy lami nate drivers The date of manufacture can be found on the nameplate or on the calibration tag These cloth epoxy drivers are tan in color and have fabric grain appearance Older drivers were red brown or dark brown and had no grain or fabric appearance Any relay field mod
5. manual Field maintenance covers periodic inspections and performance tests 32 PERIODIC PERFORMANCE TEST 3 2 1 Cleaning Before inspecting and testing the relav if necessarv use a soft cloth to clean the exterior to remove anv 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 3 2 2 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 inspec tions 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 4 2 a Ifthe Drop Awav value D A falls below 67 of the value give
6. 2F 1B Relays Note A N433830 Base Only N433830 099 Receptacle Contact Springs Solderless Type for 18 to 20 J680179 Wire Receptacle Contact Springs Solderless Type for 14 to 16 J680165 Wire Receptacle Contact Springs Solderless Type for 10 to 12 J680181 Wire Base Basic Mounting J078455 Plate Contact Clamping Order should specify piece number of J078458 mounting base for which contact clamping plate is desired Plate Coil Clamping Order should specify piece number of J078459 mounting base for which coil clamping plate is desired Strike M321745 Tag J075828 Screws 24 40 x 3 16 Rd Hd F Self Tape Tin PI J525024 Screws 1 4 20 x 1 1 4 Rd Hd S Mach Tin P1 Not J052667 Shown Washers Lock M Not Shown J047775 Washers Plate 1 4 Stl Tin PI Not Shown J047501 Nut Hex 1 4 Stl Tin P1 Not Shown J048002 Washers Not Shown J047711 Screws 6 32 x 1 1 4 Fil Hd S Mach Tin PI J052246 Nut M267499 Screws 6 32 x 5 8 Fil Hd S Mach Tin PI J522090 Indexing Plate Order should specify piece number of Relay for which indexing plate is desired Meter Test Plug Insulated Test Plug For opening any coil or contact circuit and for removing receptacle springs Hardware for attaching mounting base to rack NOTE A When Mounting Base complete is ordered a muslin bag of parts 4 1 8 x 51 2 is included in the inner carton with the mounting base and instruction prints Bag Contains T
7. 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 in the plug in position 1 2 2 Coils Coil resistance of PN 150B relay is dependent on part number See Subsection 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 PN 150B relay are standard low voltage silver to silver impregnated carbon front and silver to silver back See Figures A l or A 3 for a pictorial representation of the contact assembly 1 2 4 Shock Indicator only applies to Part Number N322500 807 WARNING ANY RELAY SHOWING SHOCK INDICATOR ACTIVATION SHOULD BE SHOPPED BEFORE PLACING RELAY INTO SERVICE FAILURE TO ASSURE PROPER FUNCTION OF THIS RELAY MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH The shock indicator P N J680167 0012 shows red when the relay has been subjected to shock in excess of a safe level i e dropped during shipment or transport This is an indication that the relay may have mechanical damage and may not meet electrical specifications SM 4596 09 00 1 1 SECTION 1 GENERAL INFORMATION UNION SWITCH amp SIGNAL 1 3 SPECIFICATIONS The following subsections provide the electrical and mechanical specifications of the PN 150B relays covered in this manual Note The 900 series once refer
8. Closed spacer Table 4 1 over the stop pin With the relav energized against the spacer adjust the front contacts so that thev are all just closed with little or no pres sure both contact tips must be just touching Remove the spacer and insert the Back Closed spacer Table 4 1 With the relav energized against the spacer adjust the back contacts so that thev are all closed with little or no pressure both contact tips must be just touching Replace the spacer with the Heel Contact spacer Table 4 1 and check for free plav between the heel spring and the driver slot There should be no binding of the drivers or excessive plav Remove the driver clips and contact drivers Adjust the heel springs bv bending at the thin sec tions near the block so that light is visible 0 005 0 010 inches between the front and back contacts and so that they are in line with each other With the Heel Contact spacer still inserted install the contact drivers and check that the slots in the driver align with the heel springs and driver bracket If necessary adjust the driver bracket Install the contact drivers and driver clips loosely Mount the relay in its normal operating posi tion Using the nominal Front Closed spacer Table 4 1 adjust the front contacts to just closed Remove spacer and replace with the nominal Front Open spacer and adjust the front contacts to just opened Remove spacer and replace with the nominal Back Closed spacer
9. and adjust the back contacts to just closed Remove spacer and replace with the nominal Back Open spacer and adjust the back contacts to just opened With the armature fully released pull each contact driver toward the front of the relay and check that the slots in the driver remain properly engaged The heel springs should engage at least 1 2 of each narrow slot of the driver and the large slot should fully engage the thick sec tion of the bracket finger The driver shall be free of any binding in all armature positions NOTE New driver clips must be installed any time that the drivers have been removed Recheck calibration Section 4 7 SM 4596 09 00 4 11 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL 4 5 3 2 Relays with One Piece Molded Driver 4 12 If new block is used install contact block in relay frame Torque mounting screws to 10 2 inch pounds On relays just being adjusted check to see that mounting screws are also torqued to 10 2 inch pounds Check heel springs for bow and adjust as required With the relay in its normal operating position place the molded contact driver in place on the relay NOTE Nominal spacers are to be used for adjustments The min or max spacers are to be used only for special calibration problems following the guide lines of Subsection 4 5 4 When adjusting contacts using closed spacer the contacts are to be adjusted to just touch As a guide there should be no
10. more than 2 grams spring pressure between the contact tips For any contact adjusted closed using nominal spacers per Table 4 1 an 0 005 thicker spacer for the fronts and an 0 005 thinner spacer for the backs must allow the contacts to be open Both contacts should be touching at the closed spacers It is permissible for light to be perceptible on one tip but both must be touch ing no light perceptible at full stroke Insert the nominal Front Closed spacer Table 4 1 over the stop pin With the relay energized adjust the front contacts so that they are all just closed with little or no pressure both contact tips must be touching Remove the spacer and insert the Back Closed spacer Table 4 1 With the relay energized adjust the back contacts so that they are all just closed with little or no pressure both contact tips must be touching Remove the contact driver from the relay Adjust the heel springs by bending at the thin section near the block so that light is visible 0 005 0 010 inches between the front and back contacts and so that they are in line with each other Reinstall the driver on the relay Using the nominal Front Closed spacer Table 4 1 adjust the front contacts to just closed Remove spacer and replace with the nominal Front Open spacer and adjust the front contacts to just opened SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE j Remove spacer and replace with the nominal Back C
11. 0 A 3 A 2 Old Style Mounting Base for PN 150B RelayS oo ooo oooooo A 5 A 3 PN 150B Relays with One Piece Molded Contact Driver A 8 A 4 Improved Mounting Base for PN 150B Relays 00000 A 10 LIST OF TABLES 1 1 Electrical Specifications eee 1 2 4 1 Mechanical Adjustments and Hold Down Torque ooooooooo o 4 17 4 2 Calibration Valles issues 6 25 844 EPEE EEEE OR eS 4 17 li SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 1 GENERAL INFORMATION 1 1 INTRODUCTION This service manual covers the PN 150B Plug In DC Biased Relay used for line and logic circuit applications requiring contact capacities up to 4 amperes Since the relay is biased it operates to ensure that the logic energy is of the proper polarity This is especially important where some circuits are polarity responsive such as switch repeating and polar line circuits PN 150B relays of earlier design are covered in Service Manual 4551 and its supplements The earlier designed relay suffixes were 0XX versus 7XX 8XX and 9XX For a given relay resistance and contact combination these second generation PN 150B relays will fit into the same mounting base and have the same operating characteristics as the corresponding earlier design relay The design of the PN 150B relay conforms to all applicable AREMA specifications 1 2 DESCRIPTION 1 2 1 General The relay is factory calibrated to operate across a wide environmental range
12. 00 706 Parts Bag Relay N322500 807 Parts Bag Relay N322500 808 Parts Bag Relay N322500 809 Parts Bag Relay N322500 810 Parts Bag Relay N381500 711 Parts Bag Relay N322500 812 Parts Bag Relay N322500 713 Screw 8 32 x 1 1 4 Hex Hd St Tin P1 Bolt Hex Hd Bz Tag Nomenclature Screw 4 x 3 16 Rd Hd Shock Indicator only for N322500 807 M434092 J5000970112 J630654 J487090 J047081 J776596 J5072950119 A043013 J079351 M433411 S003665 J791665 J4751210107 N330681 0001 N330681 0002 N332681 0003 N330681 0004 N330681 0005 N332681 0006 N330681 0007 N330681 0008 N332681 0009 N330681 0010 N330681 0011 N330681 0012 N330681 0013 J463078 M327179 J075828 J052674 J680167 0012 SM 4596 09 00 APPENDIX A PARTS LIST S UNION SWITCH amp SIGNAL MERGER SS ESSSSSSS SOSA SASS SS SSS SAAS ASA 00600000000 eooooocoooo e000000000 000000000 OI EvVG9O B6 9v Aejay JO JU014 bil m HOLVOIQNI 320HS adi EEA SRO i E SE l By qu pS J J SS SS zzz TT inen ees 3 A 3 Figure A 1 PN 150B Relays With Individual Contact Drivers SM 4596 09 00 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL A 2 PARTS LIST FOR OLD STYLE MOUNTING BASE FOR PN 150B RELAYS FIGURE A 2 Item Number Part Number Base Complete for 6BF Relays Note A N334266 Base Only N334266 099 Base Complete for 4FB
13. 437550 12 Screws SST 6 32 x 3 4 Phil Fil Hd J5072980120 13 Armature Shim M433358 14 Hinge Block J26105 0401 15 Bolt Lock J792919 16 Screw SST 28 32 x 5 8 Hex J5072950120 17 Permanent Magnet Assembly N435191 18 Strap M321853 19 SST Washer J4751210127 20 Seal Vent J790257 21 Handle J561111 22 Lock Washer SST 10 SHAK PF J4751210125 23 Screw SST 410 32 x 3 8 PH J5072960129 24 Coil Complete 25 Ohm For Relay N322500 706 806 N379650 24 Coil Complete 100 Ohm For Relay N322500 704 N321647 003 24 Coil Complete 240 Ohm For Relay N322500 705 N333975 24 Coil Complete 400 Ohm For Relay N322500 701 711 N321647 24 Coil Complete 400 Ohm For Relay N322500 801 809 901 N433498 909 24 Coil Complete 800 Ohm For Relay N322500 702 Only N321647 001 24 Coil Complete 800 Ohm For Relay N322500 802 808 902 N433498 001 908 24 Coil Complete 1300 Ohm For Relay N322500 703 Only N321647 002 24 Coil Complete 1300 Ohm For Relay N322500 803 807 903 N433498 002 24 Coil Complete 100 Ohm For Relay N322500 804 N433498 006 24 Coil Complete 4300 Ohm For Relay N322500 810 910 N33498 012 24 Coil Complete 400 400 Ohm For Relay N322500 812 N436791 25 Shim M434091 A 6 SM 4596 09 00 SM 4596 09 00 UNION SWITCH amp SIGNAL Shim Screw 1 4 20 x 3 4 Hex SST Spring Operating Arm Name Plate Order should specify piece number of relay for which Name Plate is desired Indexing Pin Gasket Cover L
14. PLY Figure 4 4 PN 150B Relay Test Circuit 47 7 CALIBRATION REQUIREMENTS 4 7 1 In Service Test Calibration requirements will be met when the relay adjustment values are the same as those given in Table 4 2 of this manual After any shop adjustments are made check the calibration values Section 4 6 and if they are not within the values given in Table 4 2 of this manual the relay should not be placed in service 4 7 2 Contact Resistance Resistance of front contacts should be measured with the armature in its full stroke position and resis tance of back contacts should be measured with the armature fully released Cleaned contact resis tances should not exceed the following values Ohms Ohms Type of Contacts Front Contacts Back Contacts Silver to Silver Impregnated Carbon 0 09 Silver to Silver 0 03 Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive load ing or an accidental short through the contacts When contacts must be dressed refer to Subsection 4 2 3 Visually inspect per Subsection 4 2 1 prior to sealing 4 16 SM 4596 09 00 UNION SWITCH amp SIGNAL SECTION 4 SHOP MAINTENANCE Min Hold Arm Air Arm Down um eae Relay Gap in Stroke Grams ap d PN 150B 0 026 0 117 190 0 038 0 043 0 076 0 081 0 032 0 037 0 082 0 087 0 042 0 047 0 078 0 083 May be reduced to 0 110 to meet calibration values NOTE Nominal spacers shall be
15. TING BASE PN 150B RELAYS FIGURE A 4 Base Complete for Wayside Relays See Note A N451376 0302 Base Only N451376 0301 Base Complete for Car Carrying Relays See Note A N451376 0303 Base Mounting Molded J780055 Strike Relay J792848 Nut Speed Push on J480280 Spring Cont Receptacle M451142 2702 Screw SST 1 4 20 x 1 1 4 Rd J5001360120 Washer SST LOCK 1 4 J4751210111 Washer SST 1 4 Plate J4751200112 Nut 1 4 20 SST Hex J4802110108 Tag Relay Identification J075951 Sheet Instr Form 8 S000008 Bag Plastic J078399 Extraction Tool J772383 NOTE A When Mounting Base complete is ordered a plastic bag of parts is included in the inner car ton with the mounting base and instruction prints Bag Contains Tags Item 10 Screws Item 6 Items 6 7 8 and 9 which are for attaching mounting base to rack Included receptacle contact springs are normally M451142 2702 for 14 and 16 wire unless other wise specified If other wire size is used the proper part number M451142 2701 for 718 20 M451142 2703 for 10 12 should be specified when ordering the complete base i e N451376 0302 except using receptacle contact springs solderless M451142 2703 SM 4596 09 00 A 9 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL DOK 19 32 pl DODODOR DODOL aid LS 19 Pager l4 Oo BEBER Hias 1 E E FRONT 2 5 E jam m l t SOLAS SAN D ue is j sil CT a
16. UNION SWITCH amp SIGNAL e E Service Manual 4596 Batesburg SC 29006 DC Biased Vital Relav Second Generation PN 150B Part Numbers Na22soo 701 702 703 ms 705 706 mm ms IN322500 801 802 803 804 806 807 808 809 810 812 N322500 901 902 903 7907 908 909 9107 September 2000 2000 Union Switch amp Signal Inc An Ansaldo Signal Company Printed in U S A Revision Index Revision Date March 1985 March 1986 October 1986 April 1987 Februarv 1988 September 2000 UNION SWITCH amp SIGNAL TABLE OF CONTENTS Table of Contents Section Subject Page No 1 GENERAL INTRODUCTION cece cece cece rere ences 1 1 1 1 INTRODUCTION 511535355 Ries ena vex ae eERC nes bed Ba AT c 1 1 1 2 DESCRIPTION rocca cud D tc Lp prop per z ae 1 1 1 2 1 General ipo AO RD TR DR RA ORD OE ane aq jk l 1 1 2 2 COS reed GAS a ech Whe HA 1 1 1 2 3 Contacts ss RARE en ke b er ay ai bee 1 1 1 2 4 Shock Indicator only applies to Part Number N322500 807 1 1 1 3 SPECIFICATIONS a i Ai A Inf pd o l 2 1 3 1 Electrical iebes fa gi he be heed L K ls Tana tifta l 2 1 3 2 Mechanical so me AAA hee bese sees AR 1 3 2 INSTALLATION kata ir ERE TERNI QS AURA UR 2 1 2 1 GENERAL cc ii a a A LT E EE AE 2 1 2 2 MOUNTING BASE ss 2 1 2 3 RELAY INDEXING ca 2 1 2 4 RECEPTACLE CONTACT SPRINGS 0 0 c cece eee eens 2 2 2 4 1 Old Style Base Only sissa na
17. URES ARE NOT FOL LOWED THE RELAY MAY NOT FUNCTION PROPERLY 9 Perform a final visual inspection once the cover and seal have been applied Pay particular attention to the permanent magnet area and the inside of the cover SM 4596 09 00 4 3 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL Poa DE Hinge Spring Stop Pin Area Teflon Tape In ES Permanent Magnet Magnet Extension Stop Pin Counterbored Hole Contact Springs FIGURE 4 1 RELAY PARTS LOCATION 4 4 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 4 2 2 Armature Stop Pin Conditioning The following instructions are for conditioning the armature stop pin See Figure 4 2 This procedure should be followed wherever a relav is shopped for failure to meet its calibration specifications during scheduled field inspection and tests a After removing the cover clean the stop pin and adjacent surface bv saturating a paper strip C contained in J793094 with Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or equivalent and then placing it between the armature and pole face Apply moderate pressure on the arma ture and draw the paper out Continue until no residue is removed from the surfaces Dry the surfaces using a clean strip of paper 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 Insert the Stop Pin Conditioning Graphite Stick N451151 3203 between the a
18. ags Item 6 Screws Item 7 Items 8 9 10 11 and 12 which are for attaching mounting base to rack and required quantity of receptacle contact springs solderless J680165 for 14 to 16 wire If other wire size is used request the proper part number as shown in Item 1 when ordering base complete i e N334266 except using receptacle contact springs solderless J680181 A 4 SM 4596 09 00 APPENDIX A PARTS LIST S UNION SWITCH amp SIGNAL co a CI C3 co ES XSAN Bam w FOR REMOVAL APPLY AECEPTACLE RE Se a 8t wrweS 310 142219 x JAQ W tiav o it o 9 S327100D gl AZ dap DIM ALA SJJEJUOD 449 WIM LY 104 oseg UNUNOW 104 aseg UNUNOW OESEEPN 99ZPEEN MOTA ILIY MOTA ILIY N NMOQ 301 9NI201 HAIA SDNIN AS 310Y1d4323M Al ddV gt il Cji HO Style Mounting Base for PN 150B Relays 2 Old Figure A A 5 SM 4596 09 00 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL A 3 PARTS LIST FOR PN 150B RELAY WITH ONE PIECE MOLDED DRIVER FIGURE A 3 Item Number Part Number 1 Frame M433355 2 Latch Rod M388888 3 Roll Pin J487087 4 Nut 006 x 5 16 Steel Lock M275388 5 Latch M321728 6 Dowel Pin J048716 7 Spring M321861 8 Armature Assembly N438599 9 Arm Molded Operating M373632 001 11 Contact Block Relays N322500 907 908 909 N438690 11 Contact Block Relavs N322500 711 N438844 11 Contact Block For Relavs not listed above N
19. al 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 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 is determined by the placement of the holes in the num bered vertical rows of the large white nylon indexing plate that 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 that 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 4596 09 00 2 1 SECTION 2 INSTALLATION UNION SWITCH amp SIGNAL WARNING NEVER 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
20. e ee aed Paw par ba i dedu 2 2 2 4 2 Improved One Piece Base Only 0 0 00 eee eens 2 2 2 4 3 Installing Wires in Receptacle Contact Springs oooooooo o o 2 4 25 RELAY INSERTION uu poesi ik PDR Pa Ae mk f i a 2 4 3 FIELD MAINTENANCE ccc ccc ee ee ccc ce eee eee 3 1 3 1 INIRODUG ON zd A dab tr dh igh dvds Reg duds dak ib oe s 3 1 3 2 PERIODIC PERFORMANCE TEST jkssentsestessbibijetih be RE de 3 1 3 2 1 Clean gi iii tacit D a a a ha pe eat AN TA a aly qe dt a ty 3 1 32 2 Service Requirements 0 0 0 cece rs 3 1 4 SHOP MAINTENANCE 55r ERE ER ROG SER a P ES 4 1 4 1 INTRODUCTION sis piki E PES a ACE ach sew ach ack ATE Nan 4 1 42 CLEANING AND INSPECTION ico a REOR RE E Eds 4 1 42 1 Cleaning and Inspection Procedure 4 1 4 2 2 Armature Stop Pin Conditioning llle 4 5 4 2 3 Cleaning Relay Contacts 2 0 0 0 ee 4 6 4 3 CHECK OUT PROCEDURE Performance Test ooo ooooo o o 4 7 4 4 REPAIRS AND REPLACEMENT 00000 e eee eee eens 4 7 4 4 1 Disassembly vd A ER lada 4 7 442 REASSCMADIY eg evan ens f a BE Seg BE BERS EE Bach Oh te Oh te AO 4 8 4 4 3 General Parts Replacement 00 4 8 4 5 ADJUSTMENTS 2 cad doe do oen navn de dab RARER LAGER d 4 9 4 5 1 Recommended Tools and Test Equipment 0 000 4 9 4 5 2 Magnet and Magnet Extension 0 0 eee eee ne 4 9 4 5 3 Contact Adjustments 0 2 0 0 cece cee eee nas 4 9 4 5 4 Adjustments To Meet Calibration Values
21. e 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 3 making sure that the shunt between the magnet and the magnet extension 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 heads after the adjust ments are made 45 ADJUSTMENTS All adjusting and testing must be done with the relay in its normal upright position 4 5 1 Recommended Tools and Test Equipment Gap Gauge 0 001 in to 0 200 in Gram Gauge 250 Grams Screw Driver Torque Measuring 4 5 2 Magnet and Magnet Extension Insert a 0 117 inch spacer between the stop pin and the pole face and adjust the permanent magnet extension so that it touches the Teflon back stop tape or the back stop pins whichever is present on the bottom of the armature After adjustment the magnet and magnet extension should be centered on each other and on the arma ture On relays without back stop pins the bottom of the armature should fit flush on the surface of the magnet extension with no air gaps On relays with back stop pins the air gap should be of uni form width across the surface of the magnet extension 4 5 3 Contact Adjustments NOTE Contacts should be adjusted when a new contact block is installed or wh
22. en the relay does not meet the calibration requirements SM 4596 09 00 4 9 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL ADJUSTABLE SHUNT MAGNET MAGNETIC SHUNT POLE PIECE 1 13 16 MAGNET EXTENSION i TER Ref PHOSPHOR BRONZE OR STEEL SCREW AS REQUIRED FIGURE 4 3 ASSEMBLY OF PERMANENT MAGNET AND ADJUSTMENT OF ARMATURE POSITION INDICATOR 4 5 3 1 Relays With Individual Contact Drivers 4 10 Refer to Subsection 4 5 3 2 for relays with one piece molded drivers If a new block is used install contact block in relay frame Torque mounting screws to 10 2 inch pounds On relays just being adjusted check to see that mounting screws are also torqued to 10 2 inch pounds Align the fingers of the driver bracket with each other and parallel with the armature NOTE When adjusting contact springs do not bend the heavy members termi nals Rough align the heel springs with each other and straighten if necessary to correct for bowed springs Perform a bowing check of the contact drivers by laying the bowed side down on a flat surface and pushing down on one end Check the other end with a 0 010 inch spacer and if the clear ance is greater than 0 010 discard the driver With the relay in its normal operating position install the contact drivers and the driver clips loosely to be removed later SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE f Insert the nominal Front
23. et switch SI to Reverse Relay should deenergize h Set switch SI to Normal Relay should again energize i Adjust dc power supply output control to reduce the current at a rate so as not to overshoot the actual value and measure the Dropaway which is the value at which the front contacts open refer to Table 4 2 for acceptable value j Further reduce the dc power supply output control setting at a rate so as not to overshoot the actual value and check Full Dropaway which is the value at which the armature rests against the permanent magnet refer to Table 4 2 for acceptable value k Reduce current to zero then open circuit momentarily using switch S2 1 Adjust dc power supply output control to increase current at a rate so as not to overshoot the actual value and obtain Pickup which is the value at which the front contacts make Refer to Table 4 2 for acceptable values m Further increase the dc power supply output control at a rate so as not to overshoot the actual value to obtain the relay Full Stroke value which is the value at which the armature is tight up to its stop pins Frequently Pickup and Full Stroke will be the same value n Test concluded Disconnect test circuit and return relay to service if it meets the calibration val ues If relay does not meet calibration values check adjustments per Section 4 5 SM 4596 09 00 4 15 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL AMMETER POWER VOLTMETER SUP
24. exan Screw 8 32 x 7 16 FH SST Seal Wire Seal Armature Spring Calibration Tag Adhesive Film for applying Ref 39 Washer LK 6 SST Parts Bag Relay N322500 701 801 901 Parts Bag Relay N322500 702 802 902 Parts Bag Relay N322500 703 803 903 Parts Bag Relay N322500 704 804 Parts Bag Relay N322500 705 Parts Bag Relay N322500 706 806 Parts Bag Relay N322500 807 Parts Bag Relay N322500 808 908 Parts Bag Relay N322500 809 909 Parts Bag Relay N322500 810 910 Screw 6 32 x 1 4 Hex SST Bolt 8 32 x 1 1 4 Stl Bolt Hex lid Bz Tag Nomenclature SST Washer Indicator Arm Pos APPENDIX A PARTS LIST PARTS LIST FOR PN 150B RELAY WITH 1 PIECE MOLDED DRIVER FIGURE A 3 CONTINUED M434092 J5000970112 M349785 J630654 J487090 J047081 J776596 J5072950119 A043013 J079351 M433411 S003665 J791665 J4751210107 N330681 0001 N330681 0002 N332681 0003 N330681 0004 N330681 0005 N332681 0006 N330681 0007 N330681 0008 N332681 0009 N330681 0010 J5072980121 J463078 M327179 J075828 J4751210127 M432380 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL S i DT iy hu z 2 I y f 24743432 to 0600009000 0090p08000 909009000600 00000000060 Figure A 3 PN 150B Relays With One Piece Molded Contact Driver SM 4596 09 00 UNION SWITCH 8 SIGNAL APPENDIX A PARTS LIST A 4 PARTS LIST FOR IMPROVED MOUN
25. hm For N322500 702 Only Coil Complete 800 Ohm For Relays N322500 802 808 902 908 Coil Complete 1300 Ohm For N322500 703 Only Coil Complete 1300 Ohm For Relays N322500 803 807 and 903 Coil Complete 100 Ohm For Relay N322500 804 Coil Complete 4300 Ohm For Relays N322500 810 910 Coil Complete 400 400 Ohm For Relay N322500 812 Coil Complete 2730 Ohm For Relay N322500 713 Shim M433355 M388888 J487087 M321728 J048716 M321861 N433399 M433403 M433404 N433831 N433354 J5072980120 M433358 J026105 0401 J792919 J5072950120 N435191 M321853 J4751210127 J790257 J561111 J4751210125 J5072960129 N379650 N321647 003 N333975 N321647 N433498 N321647 001 N433498 001 N321647 002 N433498 002 N433498 006 N433498 012 N436791 N321647 008 M434091 APPENDIX A PARTS LIST APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL A 1 PARTSLIST FOR PN 150B RELAY WITH INDIVIDUAL CONTACT DRIVERS FIGURE A 1 CONTIN UED Part Number Shim Screw 1 4 20 x 3 4 Hex SST Name Plate Order should specify piece number of relay for which Name Plate is desired Indexing Pin Gasket Cover Lexan Screw 8 32 x 7 16 FH Seal Wire Seal Armature Spring Calibration Tag Adhesive Film for applying Ref 39 Washer SST LK 6 Parts Bag Relay N322500 701 Parts Bag Relay N322500 702 Parts Bag Relay N322500 703 Parts Bag Relay N322500 704 Parts Bag Relay N322500 705 Parts Bag Relay N3225
26. ified or repaired that has the older drivers should be assembled to include the glass epoxy drivers PN 150B relays are also manufactured in a style utilizing a molded driver instead of the individual dri vers Since the contacts are the only wearing parts in this relay in most cases the relay can be restored to proper operation by cleaning Subsection 4 2 2 and readjusting them Subsection 4 5 3 4 4 1 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 sequence 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 as required SM 4596 09 00 4 7 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL NOTE These magnets are of a special alloy that 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 where there is special equipment to fully charge the magnet and then age it to its best working strength 4 4 2 Reassembly Reassembly is accomplished general
27. ing 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 pkg of 5 Burnishing Tool P K Neuses Co No N318 Heavy Duty J397187 001 pkg of 5 Paper Strip strips cut from 67 pound white Springhill Vellum Bristol Paper J793094 pkg of 50 Also recommended Emery Paper Wet or Dry 600 Grit cut in strips Commercially Available Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or Equivalent Commercially Available Stop Pin Conditioning Graphite Stick N451151 3203 4 2 1 Cleaning and Inspection Procedure The following procedure reference Figure 4 1 should be performed any time the cover is removed from the relay for inspection or any type of maintenance Only after this procedure is performed may the cover be reinstalled on the relay The cover should only be removed from the relay in a clean work area 1 e an area free of any metal particles dirt or other material that may interfere with the proper operation of the relay SM 4596 09 00 4 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL NOTE The use of an inspection magnifving lens is suggested for the following procedure 1 Carefullv examine the permanent magnet area including the magnet extension for anv pa
28. losed spacer and adjust the back contacts to just closed k Remove spacer and replace with the nominal Back Open spacer and adjust the back contacts to just opened 1 Repeat adjustment h to k until each contact is open on its respective open spacer and closed on its respective closed spacer m Check to see if heels are floating Adjust heel clip as required NOTE When the armature is held at mid stroke with neither fronts nor backs making all heel springs should ideally rest flat against the bottom edge of the driver slot For those relays which do not meet the above condi tion there is a maximum clearance allowable between the bottom of the heel spring and driver slot measureable by a 0 010 feeler gauge not going between the spring and the driver slot Under no circumstances 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 dri ver The driver clip on the armature has slotted holes to allow the clip to be adjusted so that no rubbing is evident n Recheck calibration Section 4 7 4 5 4 Adjustments To Meet Calibration Values The contact adjusting spacers and armature stroke may vary from the values in Table 4 1 if the follow ing rules are adhered to NOTE It should be understood that the following listed variations from standard adjustments are permissible only when necessary to make individual relays meet calib
29. ly in the reverse order of disassembly The following subsections provide additional instructions to be followed during reassembly of the relay 4 4 5 General Parts Replacement Do not overtighten or force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in Section 4 6 4 4 3 1 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 torqued 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 If it is necessary to install a used contact block from another relay remove only one of the dowel pins from the frame Carefully press the block on the remaining pin and fasten in place with the screws torqued to 10 2 inch pounds One dowel pin will adequately hold the block in place Do not overtighten or force parts when reassembling a relay Upon completion of reassembly calibrate the relay as directed in Section 4 6 4 8 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 4 4 3 2 Permanent Magnet The polaritv of the magnet should be such that the top end farthest from the two notched holes will attract th
30. n b If the Full Drop Awav value F D A falls below 33 of the value given c Ifthe Full Stroke value F S increases to more than 110 of the value given 3 2 2 3 Test Procedures Test the operating characteristics of the PN 150B relays as given in Section 4 6 in this manual SM 4596 09 00 3 1 SECTION 3 FIELD MAINTENANCE UNION SWITCH 8 SIGNAL This page is intentionally blank 3 2 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 4 1 INTRODUCTION This section provides the information necessary to perform shop level repairs of the PN 150B 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 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 physical damage Remove the cover and proceed with inspection cleaning stop pin conditioning and relay contact clean
31. o bronze screws The steel screw J463078 has dull tin plating and its head is 3 32 inch thick The bronze screw M327179 has brighter nickel plating and its head is 1 8 inch thick Any change in the hold down force will affect the relay calibration as discussed in Sections 4 6 and 4 7 4 5 6 Contact Openings In obtaining proper calibration it is permissible to vary the adjustments given in the foregoing subsec tions however a With the armature in its fully released position the front contacts must be open at least 0 050 inch b When a front contact is just making the corresponding back contact must be open more than 0 020 inch 4 6 CALIBRATION 4 6 1 Recommended Test Equipment Test Equipment Power Supply 0 70 Vdc Digital Multimeter two required DPDT double pole double throw S1 SPST Switch S2 4 14 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 4 SHOP MAINTENANCE 4 6 2 Procedure Connect the circuit as shown in Figure 4 4 and proceed as follows a Set ammeter to appropriate current range b Set voltmeter to appropriate voltage range c Set dc power supplv to appropriate output range d Set switch SI to Normal e Turn dc power supply on and close S2 f Observe ammeter and adjust dc power supply output control to obtain the charge current read ing 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 S
32. ration and timing requirements a The Back Just Make Spacer must always be at least 0 031 greater than the Front Just Make Spacer To provide 0 020 AREMA minimum transfer opening b The armature stroke must be at least 0 070 greater than the Front Just Make Spacer To pro vide 0 050 AREMA minimum contact opening c The difference between the front open and front closed or back open and back closed should not exceed the values given in Table 4 1 SM 4596 09 00 4 13 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL d The Front Just Make Spacer should never be less than 0 032 80 of the 0 040 average value for PN 150B front contacts e The armature stroke should always be at least 0 030 greater than the Back Just Make Spacer 80 of the average 0 38 value for PN 150B backs 4 5 5 Hold Down Force With the relay in the normal upright position and deenergized a force of at least 190 grams refer to Table 4 1 should be required to move the armature away from the permanent magnet assembly This upward force should be measured with a gram gage at the bottom end of the centermost contact driver The hold down force can be increased 1f necessary by bending away from the permanent magnet the shunting strip which is fastened to its forward face If one or both of the two vertical screws which fas ten the permanent magnet assembly to the relay frame is steel a further increase in hold down force can be obtained by changing t
33. red to relays with Lexan covers while the 800 series had covers made from a different material This material is no longer used so all relay covers are Lexan The 900 series is obsolete and the 800 series is the direct replacement 1 3 1 Electrical Relay electrical specifications are tabulated below Energization System Voltages 701 6FB Std 0 0132 10 6EB Std OE en pn B Std 1300 0 0082 10 7 pal a 1B Std 800 0 0105 8 4 gp PA em IB Std 400 0 0132 5 3 2B Std 400 0 0132 5 IN322500 l 81 All relays are presently furnished with a Lexan cover 801 N322500 80 m x E o N N322500 l 80 80 80 gt 1322500 80 IN322500 80 IN322500 80 IN322500 81 N 1322500 1 d 9v 1 1 ew 1 Y ojo Du 1 N LI Normally used in series with another relay Contacts Standard Std 4 amps low voltage silver to silver impregnated carbon front and silver to silver back Mounting Base N451376 0302 improved style for all relays above N433830 old style for relays N322500 807 808 809 N334266 old style for all other relays above TABLE 1 1 ELECTRICAL SPECIFICATIONS 1 2 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 1 GENERAL INFORMATION 1 3 2 Mechanical The following mechanical specifications are common to all PN 150B relays covered in this manual Relav Dimensions Temperature Indexing Weight Mounting Base Weight Mounting Ba
34. ring 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 After insertion pull firmly on the wire to make certain the receptacle contact spring is locked in the cavity 2 2 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 2 INSTALLATION INDEXING PINS INDEX PLATE MOUNTING BASE FIGURE 2 1 TYPICAL PLUG IN RELAY AND MOUNTING BASE MOUNTING BASE RECEPTACLE SPRING ove snes ye aan sen ena omen o ane win sine ol RECEPTACLE SPRING OLD MOUNTING BASE NEW MOUNTING BASE FIGURE 2 2 RECEPTACLE SPRING INSTALLED SM 4596 09 00 2 3 SECTION 2 INSTALLATION UNION SWITCH amp SIGNAL 2 4 3 Installing Wires in Receptacle Contact Springs Use the following procedure to ensure a good electrical and mechanical connection between the con ductor wire and the receptacle contact spring The following table identifies the correct crimping tool to be used when installing wires in receptacle contact springs Crimping Tool Old Style Improved Base Receptacle Receptacle Amp Type Wire Size Contact Spring Contact Spring 2 3 J397138 7210 7212 AWG J680181 M451142 2703 J397139 214 716 AWG J680165 Std M451142 2702 J397188 18 20 AWG J680179 M451142 2701 Strip 3 16 in 0 187 in or 0 47 cm of ins
35. rmature stop pin and its point of contact on the pole face with graphite against stop pin While applying moder ate pressure on the stick pull the stick back and forth in a circular motion over the stop pin continuing several seconds to ensure a sufficient amount of graphite transfer It is not necessary to observe a significant deposit 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 Stop Pin Graphite Stick FIGURE 4 2 PN 150B RELAY SM 4596 09 00 4 5 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL 4 2 3 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 require ments the contacts should be cleaned in accordance with the following procedures NOTE In the final cleaning procedures outlined in the following sections it is recommended that all silver contacts be cleaned first and then all silver impregnated carbon contacts in order not to contaminate the silver tips with residue that might adhere to the cleaning tool from cleaning the sil ver impregnated carbon contacts NOTE When using the paper strip clean the back contacts first then the front contacts last Discard the paper strips when dirty 4 2 3 1 Contacts That Are Severely Burned
36. rti cles that mav interfere with the proper operation of the relav such as dirt fibers metal slivers etc Use compressed air to blow out the particles or wipe the area to remove the particles CAUTION MAINTAIN A LOW AIR PRESSURE 10 TO 50 PSI OR ELSE DAMAGE MAX OCCUR TO THE CONTACT SPRINGS CLEAN OR FILTERED AIR SHOULD BE USED AT ALL TIMES OR ELSE CONTAMINATION MAY RESULT CARE MUST BE TAKEN SO THAT PARTICLES ARE NOT MOVED TO ANOTHER PART OF THE RELAY 2 Examine the stop pin counterbored hole located on the bottom of the armature for any parti cles Use compressed air to blow out any particles If the particle cannot be removed via com pressed air the particle should be checked to see if it is loose and has a possibility of becoming dislodged This check can be performed by using a sharp tool resembling an angled dental pick to dislodge the particle 3 Move the armature to the energized position and examine the space between the armature and the face of the magnet extension This area must be clean and free of any particles Pay special attention to the teflon tape see note below which is located on the bottom of the armature CAUTION PARTICLES CAN BECOME EMBEDDED IN THE TEFLON TAPE REMOVE ANY SUCH PARTICLES OR THEY MAY INTEFERE WITH THE PROPER OPERATION OF THE RELAY 4 Move the armature to the deenergized position and examine the area between the armature and the pole faces Use compressed air to blow out any particles
37. se Dimensions SM 4596 09 00 Height 7 1 16 17 93 cm Width 2 7 16 6 19 cm Depth 8 7 32 20 88 cm 40 F 40 C to 185 F 85 C Refer to Section 2 3 6 3 4 Lbs 17 5 oz Old style Base 9 5 oz Improved Base Height 7 15 16 20 16 cm Width 2 7 16 6 19 cm Depth 2 7 16 6 19 cm Old Style Base Depth 1 25 32 4 52 cm Improved Base SECTION 1 GENERAL INFORMATION UNION SWITCH amp SIGNAL This page is intentionally blank 1 4 SM 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 2 INSTALLATION 2 1 GENERAL Relays plug directly into a mounting base that is secured to a rack The only installation instructions required are for the mounting base 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 receptacle contact springs Mounting base details are shown in Figures A 2 Old Style Base and A 4 Improved Base of the Appendix 2 3 RELAY INDEXING Relays are factory equipped with indexing pins to prevent insertion of an incorrect relay into a mount ing base Each relay is accompanied by an indexing plate that 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 manu
38. ulation from the end of the wire 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 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 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 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 RELAY INSERTION 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 4596 09 00 UNION SWITCH 8 SIGNAL SECTION 3 FIELD MAINTENANCE 3 1 INTRODUCTION This section provides the necessarv periodic preventive maintenance procedures which must be per formed to ensure continuous proper and efficient operation of the PN 150B relavs covered in this
39. used for standard adjustments The minimum maximum spacers are used for special calibration problems In that case always maintain 0 020 transfer open and 0 050 full stroke TABLE 4 1 MECHANICAL ADJUSTMENTS AND HOLD DOWN TORQUE Minimum Min Full Max Pick Up Drop Away Drop Away amp Full Stroke 1300 800 400 240 100 25 4300 400 400 2730 For this dual coil relay each coil must be checked separately TABLE 4 2 CALIBRATION VALUES SM 4596 09 00 4 17 SECTION 4 SHOP MAINTENANCE UNION SWITCH 8 SIGNAL This page is intentionally blank 4 18 SM 4596 09 00 UNION SWITCH amp SIGNAL A 1 Parts List for PN 150B Relay with Individual Contact Drivers Figure A 1 tem Number Part Number SM 4596 09 00 Frame Latch Rod Roll Pin Deleted Latch Dowel Pin Spring Armature Assembly Contact Driver Driver Clip Contact Block Relays N322500 807 808 809 Contact Block For Relays not Listed Above Screws 6 32 x 3 4 FH SST Armature Shim Hinge Block Bolt Lock Screw 8 32 x 5 8 Hex SST Permanent Magnet Assembly Strap Washer SST 170 ID FLT Seal Vent Handle Lock Washer 10 SHAK PF Screw 10 32 x 3 8 PH SST Coil Complete 25 Ohm For Relay N322500 706 806 Coil Complete 100 Ohm For Relay N322500 704 Coil Complete 240 Ohm For Relay N322500 705 Coil Complete 400 Ohm For N322500 701 711 Coil Complete 400 Ohm For Relays N322500 801 809 901 909 Coil Complete 800 O
40. w CN KID EET ET a 0000 TO OPEN CIRCUIT ra APPLY ABOVE RECEPTACLE SPRING FOR REMOVAL APPLE M BELOW RECEPTACLE SPRING PULL ON WIRE Figure A 4 Improved Mounting Base for PN 150B Relays SM 4596 09 00
Download Pdf Manuals
Related Search