SM-4551M - Ansaldo STS
Contents
1. i rN FIGURE 4 1 ARMATURE STOP PIN LOCATION a After removing the cover clean the stop pin and adjacent surface by saturating a paper strip contained in J793094 with alcohol and placing it between the armature and pole face Apply moderate pressure on the armature and draw the paper out Continue until all residues are removed from the surfaces Dry the surfaces using a clean strip of paper b Apply a dry lubricant such as graphite to the relay stop pin and its point of contact on the pole face 1 Insert the stop pin conditioning graphite stick N451151 3203 between the armature stop pin and its point of contact on the pole face with the graphite against the stop pin While applying moderate pressure on the stick pull the stick back and forth in a circular motion over the stop pin for 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 C Recheck relay calibration and prepare relay for return to service 4 3 CHECK OUT PROCEDURE PERFORMANCE TEST Perform calibration in accordance with Section 4 6 4551 M 09 00 4 3 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL 4 4 REPAIRS AND REPLACEMENT Since the contacts are the only wearing parts in this relay in most cases the relay can be restored to proper operation by dressing Section 4 2 and readjust2. per 544 Ax 19 c fr a BR O40 lo 5 H lt zz ui c pt cos oz 251 FIGURE 2 OLD STVLE MOUNTING FOR PN 150BM RELAYS 4551 M 09 00 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL PARTS LIST FOR IMPROVED MOUNTING BASE PN 150BM RELAYS SEE FIGURE A3 ITEM PART NO DESCRIPTION NO 1a N451376 0302 Base Complete for Wayside Relays 14 16 contacts Note A 1b N451376 0301 Base Only 1c N451376 0305 Base Complete for Wayside Relays 10 12 contacts Note A 2 J780055 Base Mounting Molded 3 147792848 Strike Relay 4 J480280 Nut Speed Push On 5 1 451142 2702 Spring Cont Recept 6 JO52667 Screw 1 4 20 x 1 1 4 Rd 7 4047775 Washer 1 4 Sti Lk Med 8 J047501 Washer 1 4 Stl Plate 9 J048002 Nut 1 4 20 IJNC 2B Hvy 10 J075951 Tag Relay Identification 11 S000008 Sheet Instr Form 8 12 J078399 Bag Plastic 13 J772383 Extraction Tool Used for opening any coil or contact circuit and for removing receptacle springs Note A When Mounting Base complete is ordered a plastic bag of parts is included in the inner carton with the mounting base and instruction prints Bag Contains Tags Item 10 Screws Item 6 Items 6 7 8 and 9 for attaching mounting base to rack Included receptacle contact springs are normally M451142 2702 for 14 and 16 wire unless otherwis
3. 09 00 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL A 1 continued PARTS LIST FOR PN 150BM MAGNETIC HEAVY DUTY CONTACT RELAYS N322517 XXX N322524 XXX N322525 XXX SEE FIGURE A1 Relay Part No Description Item all M321761 Relay Frame 5 M388888 Latch Rod 10 al 1 321728 Latch Machined 25 17048716 Pin Roll SST 30 1 321861 Spring Plated 35 PN375963 Armature 40 al 1 291657 Washer 45 all 17052243 Screw 6 32x7 16 Fil Hd 50 al N375952 Block Contact 55 all 17052603 Screw 8 32x7 8 Rd Hd 60 all M432380 Indicator Arm Pos TO M275388 Nut 006x5 16 Steel Lock 75 al 14463077 Bolt 6 32x3 4 Hx Hd Steel 80 JPM399699 Permanent Magnet Assembly 87 all M321853 Strap Magnet Steel 90 17792919 Bolt Lock Monel Met 95 all 561111 Handle Pull Aluminum 100 all J475121 0125 Whsr SST 10 Shak Pf 105 507296 0129 Scr SST 10 32x3 8 PH 110 all 17463078 Bolt 8 32x1 1 4 Steel 115 al 1 327179 Screw a Hex Hd Bronze Rd 115 all M347526 Spacer 0548x48x120 Steel Sht 120 M349785 Spring 26 Phos Bronze Rd 125 al M376053 Spacer 2x 7 8 Aluminum 130 all M312123 Washer 135 all 17047714 Washer 8 Shprf LK SS 140 M373632 002 Operating 145 all J475121 0127 Washer SST 170 ID 150 517 321647 Coil Encapsulated 400 Ohms See N3
4. 1300 0 010 130 Contacts heavy duty silver to silver impregnated carbon front and silver to silver back with magnetic blowouts TABLE 1 3 CONTACT ASSIGNMENTS Contact Arrangement Number Type Circuit Fronts toward battery Pp 8 123 F CircuitFronts toward batte 2F 2B Circuit Heels toward battery 34 Circuit Heels toward batte For use with FR HI SHUNT Track Unit All relays are presently furnished with Lexan covers If relay has fronts only the front contacts go toward positive If relay has both fronts and backs the heel contact goes toward positive 4551 M 09 00 1 3 SECTION 1 GENERAL INFORMATION UNION SWITCH amp SIGNAL This page is intentionally blank 1 4 4551 M 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 3 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 mounting base Each relay is accompanied by an indexing plat
5. a 2 4 Relay IMSGMION kai 7 2 5 Visual INSPSCUOMN Re e a CAE 2 5 FIELD MAIN TENANGCE i ida bidet ddd Ed EU fat 3 1 LLO cde buco i FA oid 3 1 Periodic Performance Testa a A 3 1 3 1 Service Requirements at 3 1 gt 9 3 1 oris io 3 1 Test 3 1 SHOP MAINTENANCE 4 1 4 1 Cleaning and Inspeclion se eo 4 1 Cleaning Relay Contacts 4 1 C 5 4 2 Contacts that are Burned isum Ire aeu ete pu Den eod a dta adag 4 2 Contacts with Heavy Tarnish Slightly Rough or Pitted 4 2 Contact with Surface Film or Oxidation Not 4 2 Armature Stop Pin 4 3 Check Out Procedure Performance 4 3 Repairs and Repla ement 4 4 Recommended is ia 4 4 4551 M 09 00 TABLE OF CONTENTS UNION SWITCH amp SIGNAL 4 4 2 Disassembly dE 4 4 4 4 3 REASSEMDIV RACER 4 4 4 4 4 General Parts Replacement 2 4 5 444 1 Armature Ar G
6. 4 4 General Parts Replacement 4 4 4 1 Armature Air Gap The parallel air gap should be 023 002 The minimum rear air gap between the armature and the clamping blocks for the horizontal hinge springs is 004 at its closest point Reference Figure A1 A 4 4 4 2 Replacing Contact Block If the contact block is to be replaced by another remove the old block and then use a small punch to remove the small dowel pins Attach the new block with the four screws Torque the contact block screws to 10 2 inch pounds Run a 42 drill 0 0935 Dia through the dowel pinholes 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 frame surface If itis necessary to install a used contact block from another relay remove only one of the dowel pins from the aluminum frame Carefully press the block on the remaining pin and fasten in place with the screws One dowel pin will adequately hold the block in place Install the contact block mounting screws and torque them to 10 2 inch pounds 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 4 3 Permanent Magnet Replacement The polarity of the magnet should be such that the top end farthest from the two notched holes will attract the end
7. Location zie rated reco te we 4 3 4 2 Assembly of Permanent Magnet eese 4 6 4 3 Fleel Contact Springs 4 8 4 4 PN 150BM Relay Test 4 11 A 1 PN 150BM Relay Parts Location Diagrams A 1 A 2 Old Style Mounting Base for PN 150BM 5 7 A 3 Improved Mounting Base for PN 150BM A 9 4551 M 09 00 II TABLE OF CONTENTS UNION SWITCH amp SIGNAL This page is intentionally blank 4551 M 0 00 1 4 INTRODUCTION This manual provides service information for the PN 150BM plug in relay The PN 150BM relay is a biased relay that has magnetic blowout contacts These contacts can carry 15 amperes This relay is used to control electric switch machines The design of the PN 150BM relay conforms to all applicable AREMA specifications 1 2 SHOCK INDICATORS N322524 001 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 m
8. N330681 2403 Bag Parts N322524 003 205 525 N330681 2501 Bag For N322525 001 205 525 N330681 2502 Bag For N322525 002 205 525 N330681 2504 Bag For N322525 004 205 525 N330681 2506 Bag For N322525 006 205 all J500097 0112 Screw 14 20 x 34 Hex Hd SS 210 5000456 Tag Instruction 215 524 J680167 0012 Shock Indicator N322524 001 only 899 4551 M 09 00 A 5 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL A 2 PARTS LIST FOR OLD STYLE MOUNTING BASE FOR PN 150BM MAGNETIC HEAVY DUTY CONTACT RELAYS SEE FIGURE A2 Item Part No Description Used on Relay N376048 Mounting Base Complete with solder less type Note receptacle contact springs and mounting hardware N399689 Mounting Base Complete with solderless type C Note A receptacle contact springs and mounting hardware N432995 Mounting Base Complete with solder less type D Note A receptacle contact springs and mounting hardware 1 N376048 099 Mounting Base Only N399689 099 Mounting Base Only C N432995 099 Mounting Base Only D 2 J680181 Receptacle contact springs Solderless Type for A B C D 10 to 12 Wire J680165 Receptacle contact springs Solderless Type for A B C D 14 to 416 Wire J680179 Receptacle contact springs Solderless Type for A B C D 18 to 20 Wire 3 Screw 6 32 x 5 8 Lg Fil Hd Stl Tin LI A B C D 4 Screw 4 40 x 3 16 Rd Hd Type F Self Tapping A B C D
9. SIGNAL SECTION 2 INSTALLATION TABLE 2 2 PoLARITY MARKINGS Relay Base Marking N322517 001 N376048 On Front On Heels 002 Contacts 003 004 N322524 001 N399689 On Heel On Front amp 002 Contacts Back Contacts 003 N322525 001 N432995 On Front On Heels 002 Contacts 004 006 2 5 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 SERIES CONNECTED MULTIPLE CONNECTED IMPROVED STYLE BASE SERIES CONNECTED MULTIPLE CONNECTED OLD STYLE BASE FIGURE 2 3 EXTERNAL CONNECTIONS TO MOUNTING BASE 2 6 VISUAL INSPECTION On PN 150BM P N N322524 XXX as part of the final factory inspection a dynamic operational test at rated capacity is performed that may cause a discoloration of the contacts and contact springs This discoloration is normal and does not affect the proper operation of the relay 4551 M 09 00 2 5 SECTION 2 INSTALLATION UNION SWITCH amp SIGNAL This page is intentionally blank 2 amp 4 4551 M 09 00 3 1 INTRODUCTION This section provides the necessary periodic preventive maintenance procedures that must be performed to ensure continuous p
10. Tin PI 5 Screw 1 4 20 x 1 74 Lg Rd Rd Stl Tin PI A B C D 6 Washer Not Shown A B C D 7 Lockwasher 1 4 Steel Tin PI Not Shown A B C D 8 Hex Nut 1 4 20 steel Tin PI Not Shown A B C D 9 M322965 Meter Test Plug All 10 J077931 Insulated Test Plug for opening any coil for contact All circuit and for removing receptacle contact springs Note A When Mounting Base complete is ordered a bag of parts 4 1 8 x 5 1 2 is included in the inner carton with the mounting base and instruction prints Bag Contains 2 Tags 4 4 40 Scrs X 3 16 Rd Hd Stl T P 2 Lockwashers 74 Steel Tin Plated 2 Flatwashers 14 Hx Hd Stl T P 2 Nuts 74 Hx Hd Stl Washers 2 2 Screws 20 x 1 14 Rd Hd Stl Req Receptacle contact springs solderless J680165 for 14 to 16 wire If other Qty wire size is used request the proper part number shown in Item 2 when ordering base complete i e N376048 except using receptacle contact springs solderless J680181 Note B Items 5 to 8 inclusive are for attaching mounting base to rack and are contained in the bag shipped with the Mounting Base Complete part number A 6 4551 M 09 00 UNION SWITCH amp SIGNAL APPENDIX A PARTS LIST coerce cc fe cee C 1 c C ke L bd L N a gt ge 5 i 2 2c
11. base with the lock side down Refer to Figure 2 2 b Make certain that the lanced tab is slightly compressed as the receptacle contact spring is inserted along the top of the cavity The lanced tab could have been bent during handling and therefore 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 After insertion pull firmly on the wire to make certain the receptacle contact spring is locked in the receptacle 22 4551 M 09 00 UNION SWITCH 8 SIGNAL SECTION 2 INSTALLATION INDEXING PINS INDEX PLATE RELAY MOUNTING BASE FIGURE 2 1 TvPICAL PLUG IN RELAY AND MOUNTING BASE MOUNTING BASE RECEPTACLE RECEPTACLE SPRING SPRING OLD MOUNTING BASE NEW MOUNTING BASE FIGURE 2 2 RECEPTACLE CONTACT SPRING INSTALLED 4551 M 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 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 CRIMPING TOOLS Crimping Old Style Improved Base Contact Spring Contact Spring J397138 410 212 AWG J680181 M451142 2703 J397139 414 416 AWG 4680165 Standard M451142 2702 J3971
12. be made with the relay in the normal upright position Contact support fingers should be adjusted sideways by using the alignment tool J397164 0026 for heels and J397164 0025 for fronts and backs so that the contact tips on both members are approximately centered Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive loading or an accidental short through the contacts In case contacts must be dressed 600 grit emery paper should be used and this should be followed by the use of the burnishing tool and paper strip After the contacts are dressed and or after adjustments have been made to meet calibration reguirements clean the contacts in accordance with the instructions in Section 4 2 of this manual 4 5 5 1 Heel Contact Springs a Original Design Before adjusting the heel springs it should be determined that the dimensions exist as shown in Figure 4 3 for outside to outside across the flats of the depressions of the heel springs where the slots of the operating arm rest If they need adjusting it is done by bending springs at the outer ends After this adjustment it must be determined the springs are pressing against each other at the two points indicated Figure 4 3 and that the free ends are aligned within 1 64 of an inch 4551 M 09 00 4 7 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL TOUCHING TOUCHING 2B 2F FIGURE 4 3 HEEL CONTACT SPRINGS 4 5 5 2 Adj
13. strong use maximum spacers If the hold down force is too weak use minimum spacers gone NM NE Permanent Magnet 0 250 0 245 0 255 stop pin spacer for adjustment Assembly Back stop pins touching Front Contact Adjustment 0 046 sm Main stop pin spacer Contacts just open Front Contact Adjustment 0 043 EH Main stop pin spacer Contacts must close Back Contact Adjustment 0 041 0 035 0 045 Back stop pin spacer Contact just 4 Back Contact 0 032 Spacer between permanent magnet Compression Test and armature lower stop pins Front Contact Openings 0 130 With back contacts just closed Front Contact Openings 0 150 Armature released against permanent magnet Back Contact Openings 0 030 With operating arms removed Front Contact Openings 0 060 With operating arms removed Polarity Test Charge Plus lead on upper left mounting base Value receptacle viewed from front for pickup With reversal armature must stay down Reverse several times ren charge To open Back Contacts 4 HEEL Contact Pressure 4 8 armature ete 6 on permanent magnet Break Away from Di Differential for Break Away from Permanent Magnet permanent magnet to be less than actual Pick Up Pick up Front Contacts Table It is permissible for Pick up and Make 4 Working to be the same To Stop Pin 4 8 Hold Down Torque 150 Fo
14. 22517 003 155 517 N321647 002 Coil Encapsulated 1300 See N32251 7 004 155 517 333975 Coil Encapsulated 240 Ohms See N322517 001 155 517 JN377310 Coil Encapsulated 11 25 5 Ohms See N322517 002 155 524 321647 Coil Encapsulated 400 Ohms see N322524 002 155 524 N321647 008 Coil Encapsulated 2730 Ohms see N322524 003 155 524 N333975 Coil Encapsulated 240 Ohms see N322524 001 155 525 321647 Coil Encapsulated 400 Ohms 155 525 N321647 002 Coil Encapsulated 1300 Ohms 155 525 N333975 Coil Encapsulated 240 Ohms 155 525 N436791 001 Coil Encapsulated 220 220 Ohms 155 all J630776 PL Aluminum Name 160 all J487090 Pin Roll 3 32DX 1 1 8 165 all 14047081 Gasket Rubber 170 A 4 4551 M 09 00 UNION SWITCH amp SIGNAL APPENDIX A PARTS LIST Relay Part No Description Item al J776596 Cover Molded Relay 175 all 507295 0119 SCR SST 8032x7 16 180 all A043013 Wire Seal 23 x 12 SST 185 all 17079351 Seal Lead 190 all 5003665 Tag 195 all 10790257 Seal Adhesive Vent 200 517 N330681 1701 Bag Parts for N322517 001 205 517 N330681 1702 Bag Parts for N322517 002 205 517 N330681 1703 Bag Parts for N322517 003 205 517 N330681 1704 Parts for N322517 004 205 524 N330681 2401 Bag Parts N322524 001 205 524 N330681 2402 Bag Parts N322524 002 205 524
15. 33 of the value given C 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 150BM relays as given in Section 4 6 Calibration 4551 M 09 00 3 1 SECTION 3 FIELD MAINTENANCE UNION SWITCH amp SIGNAL This page is intentionally blank 3 2 4551 M 09 00 4 1 INTRODUCTION This section provides the information necessary to perform shop level repairs of the PN 150BM 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 carefully use a soft cloth to clean the exterior and to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc Inspect the relay exterior for signs of physical damage such as a 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 clean the surface between the armature and the pole faces especially the stop pin area see Figure 4 1 using a lint free cloth and alcohol Proceed with re
16. 88 418 220 AWG _ 4680179 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 Partially close the crimping tool jaws against the receptacle contact spring to hold itin place Do not crush the receptacle contact spring barrel at this time d Insert the stripped end of wire all the way into the receptacle contact spring barrel Squeeze the tool handles until crimping is completed and the jaws release Always attach the first wire to the longest terminal This ensures that a second lead may be attached to the receptacle contact spring at a later time 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 4 4 Base Wiring a Series or parallel connected coils Some PN 150BM relay coils can be either series or parallel connected by externally wiring the mounting base see Figure 2 3 b Polarity of current through the magnetic blow out contacts CAUTION It is imperative that the polarity of the current through the contacts of this relay be checked closely to agree with the polarity markings shown on the mounting base If the polarity is not correct the arc persisting between the contacts can seriously damage the relay 2 4 4551 M 09 00 UNION SWITCH amp
17. LAYS Adjust using nominal spacers for test numbers 1 4 for all relays If the hold down force is too strong use maximum spacers or if too weak use minimum spacers Test Acjustment Nom min Max tese per EN Assembl ment Back stop pins touching Adjustment just open n Adjustment must close Front Contact Opening 0 030 With operating arms removed Polarity Test Charge Plus lead on upper left mounting Value base receptacle viewed from front for pickup With reversal armature must stay down Reverse several times EN Table After charge To close back 4 A ka contacts LL After drop away Reduce current 4 y until armature rests on permanent magnet Break Away from ES Differential for Break Away from Permanent Magnet p a permanent magnet to be less than actual Pick Up Pick up Front Contacts as It is permissible for Pick up and Make 4 y p Working to be the same Working Full Stroke Table To Stop Pin 4 a hi Hold Down Torque 150 Force on bottom contact engaging Grms pin of operating arm to pull armature from permanent magnet after charge 11 Final Electrical Recheck tests 6 to 11 with cover Inspection applied 4 12 4551 M 0 00 TABLE 4 6 ADJUSTMENT AND CALIBRATION SUMMARY FOR PN 150BM WITH 26 28 MAGNETIC HEAVY DUTY CONTACTS N322524 XXX Adjust using nominal spacers for test numbers 1 4 for all relays If the hold down force is too
18. UNION SWITCH amp SIGNAL 645 R 15 a 2 2 Service Manual 4551 DC MAGNETIC BLOW OUT HEAVY DUTY CONTACT RELAY PN 150BM Part Numbers N322517 N322524 N322525 September 2000 An JANSALDO Signal Companv 2000 Union Switch amp Signal Inc Printed in U S A UNION SWITCH amp SIGNAL REVISION INDEX April 1998 September 2000 UNION SWITCH amp SIGNAL TABLE OF CONTENTS Section LX WN GENERAL INFORMATION gt ter epe vets 1 1 HOM Ps ADF re PC CR 1 1 Shock Indicators soa enu tete cd a CU 1 1 HH Et 1 1 096560000 d MMC Ed MESE 1 1 __ _ ___ _________ _ 1 1 _ _ _ gt lt gt 1 2 Contacts 1 2 Specifications ATA 1 2 M6CCI80 68 MTM 1 2 1 3 INSTALLATION O Y ae eee ee 2 1 22 2 2 3_ 22 3 3 lt 2 1 2 1 alive 2 1 Receptacle Contact Sprind 8 eiii skin eti Fave EXE kmiem 2 2 Old Style Bases Only 2 2 2 Improved One Piece Base Only eee 2 2 Installing Wires in Receptacle Contact 5 2 4 aas
19. ap gt __ OD EEE 4 5 4442 Replacing Contact Block et esc ten od ure e eren 4 5 4 4 4 3 Permanent Magnet Replacement sss 4 5 4 5 Pese M S 4 6 4 5 1 Recommended Tools and Test 4 6 4 5 2 Permanent Magnet Extension 4 6 4 5 3 FermanentiMa re RP 4 6 4 5 4 4 7 4 5 5 Conna Adu ncc Tn 4 7 4 5 5 1 Heel Contact Springs ae un NO pene YNAD ADN ml 4 7 4 5 5 2 Adjusting Front and Heel Contact Springs 4 8 4 5 6 Hold DOWwWM FOTCE i 4 9 4 5 7 Contact Openings xi AT 4 10 4 6 iere TRE 4 10 4 6 1 Recommended Test 4 10 4 6 2 Calibration ProOCedufe ia ii ta eea 4 10 4 6 3 Contact RESISTANCE 4 11 APPENDIX A ro dd A 1 A 1 Parts List for PN 150BM Magnetic Heavy Duty Contact Relays A 1 A 2 Parts List for Old Style Mounting Base for PN 150BM Magnetic Heavy Duty Contact A 6 A 3 Parts List for Improved Mounting Base PN 150BM Relays N322517 XXX N322524 XXX N322525 XXX A 8 List of Tables 1 1 Mechanical Specifications doa ika a Ehe red DD LO REEF ehe pb n a 1 2 1 2 Relay Electrical S
20. ate or for application to a new mounting base 4551 M 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 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 2680165 solderless receptacle contact springs and will accommodate one or two 14 or 16 wires However it can be equipped with receptacle contact springs for one or two 10 or 12 wires 4680181 or for one or two 18 or 20 wires 4680179 Make certain which type of solderless receptacle contact springs accompanies the mounting base before proceeding with their installation 2 4 2 Improved One Piece Base Only The one piece mounting base with hardware N451376 0305 includes a full comple ment of receptacle contact springs eighteen 10 M451142 2703 four 14 16 M451142 2702 for coil connection mounting fasteners and tags 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
21. be retained as replacements in relays still using such contacts Relay Pc No No Contacts Coil Res Ohms M 3522 N322524 gt 7 2F 2B Magnetic Heavy Duty 2F 2B Magnetic Heavy Duty 003 2F 2B Magnetic Heavy Duty 2730 N322525 004 Magnetic Heavy Duty 1390 006 1300 3F Magnetic Heavy Duty 220 220 aO F NR ERE SARA ORNS FIGURE A 1 A PN 150BM RELAY PARTS LOCATION DIAGRAM 4551 M 09 00 1 a UNION SWITCH amp SIGNAL APPENDIX A PARTS LIST 1 4 01285 VI01109 ul FiGURE A 1 B PN 150BM RELAY PARTS LOCATION DIAGRAM 4551 M 09 00 A 2 32V4unS JHL QNOA38 JLL3N9WA 3AON3U 1 10N 5300 IN3432 LYW ONINVI 80702 Ol 30IX0 NOU Q3H30M0d HLIM 03XIM 522 0V 143439 HLIA A 3 APPENDIX A PARTS LIST a UNION SWITCH amp SIGNAL gt Y LI r PRL FLSW WAD db os 20 or WIS 8 543955 N3H1 1 MAIA EN HOLYVOIGNI X20HS _ ao OO ASS l SL 5 53 15 aq jou snui Huned 22650 J9AJIS ICII91CVII C2 X9Uu eld 891 pue og o 1520IV0 ad Pil y Pr bs en er U PN 150BM RELAY PARTS LOCATION DIAGRAM C FIGURE A 1 4551 M
22. cer allows the contacts to close Again remove the operating arm and determine that the heel contacts have the appropriate clearance Table 4 5 or 4 6 4 8 4551 M 0 00 4 5 6 Hold Down Force a With the relay in its normal upright position energize the relay in its reverse direction armature not picking up to the Charge Value given in Table 4 7 b Pole change to pick up the armature to full stroke and then deenergize the relay p At the bottom of the centermost contact driver or at the bottom of the center of the molded driver measure the upward force in grams to move the armature away from the permanent magnet d This is the hold down grams and must not be less than the value given in Table 4 5 and 4 6 The hold down force can be increased if necessary by bending the shunting strip which is fastened to its forward face away from the permanent magnet If one or both of the two vertical screws that fasten the permanent magnet assembly to the relay frame is steel a further increase in hold down force can be obtained by changing to 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 Section 4 6 4551 M 09 00 4 9 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL 4 5 7 Contact Openings I
23. d if necessary until the armature rests against the permanent magnet This is the Full Drop Away value and it shall not be less than the minimum value specified 4551 M 0 00 h The voltage shall then be reduced to zero and after opening the circuit for one second gradually increased and the value shall be noted at which the armature moves away from the permanent magnet The armature should move away with a definite sudden motion The voltage shall be further increased until the front contacts close and the value noted The voltage shall then be further increased if necessary until the armature stop pin closes against the pole face This is the Full Stroke value and it shall not exceed the maximum value specified AMMETER DC POWER VOLTMETER SUPPLY FIGURE 4 4 PN 150BM RELAY TEST CIRCUIT 4 6 3 Contact Resistance Resistance of front contacts should be measured with the armature in its full stroke position and resistance of back contacts should be measured with the armature fully released Cleaned contact resistance should not exceed the following values TABLE 4 4 CONTACT RESISTANCE Ohms Ohms Type of Contacts Front Contacts Back Contacts Silver to Silver Impregnated Carbon 0 09 Silver to Silver 0 03 4551 09 00 4 11 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL TABLE 4 5 ADJUSTMENT AND CALIBRATION SUMMARY FOR N322517 XXX AND N322525 XXX PN 150BM RE
24. e which is applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with indexing plate is shown in Figure 2 1 The following data defines the indexing that has been established for relays covered by this manual a The index code always consists of four figures such as 0001 0002 or 0101 and is used for both the relay and the indexing plate on the mounting base b The index code for each relay can be determined from the relay part number and its suffix which is marked on the 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 thus obtained should agree with the placement of the indexing pins in the numbered vertical rows on the back of the relay starting with the top pin and reading down C The index code for each mounting base is determined by the placement of the holes in the numbered vertical rows of the large white nylon indexing plate 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 itis needed for replacement of damaged indexing pl
25. e specified If other wire size is used the proper part number M451142 2701 for 18 20 M451142 2703 for 10 12 should be specified when ordering the complete base N451376 0302 except using receptacle contact springs solderless M451142 2703 A 8 4551 M 09 00 UNION SWITCH amp SIGNAL APPENDIX A PARTS LIST R REMOVAL APPLY da _ BELOW RECEPTACLE 2 SPRING PULL ON WIRE TO OPEN CIRCUIT a APPLY ABOVE SS RECEPTACLE SPRING P FIGURE A 3 IMPROVED MOUNTING BASE FOR PN 150BM RELAYS 4551 M 09 00 A 9 APPENDIX A PARTS LIST UNION SWITCH amp SIGNAL This page is intentionally blank 10 4551 09 00
26. echanical damage and may not meet electrical specifications The relay should be opened and visually inspected for damage i e kinked springs Mechanical settings should be checked recalibrated and tested according to specifications by a qualified individual 1 3 TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link R A I L Team is comprised of experienced product and application engineers ready to assist and resolve technical issues concerning any US amp S product Any questions regarding the contents of this Service Manual can be answered by contacting the Team via e mail at railteam switch com or a toll free call to 800 652 7276 1 4 DESCRIPTION 1 4 1 General The PN 150BM plug in relay is a biased relay used in control of electric switch machines The relay is factory calibrated to operate across a wide environmental range All moving parts are enclosed in a sturdy transparent dust and moisture resistant cover To ensure the relay is inserted in its proper mounting base all relays have indexing pins Relays lock securely in the plug in position 4551 M 09 00 1 1 SECTION 1 GENERAL INFORMATION UNION SWITCH amp SIGNAL 1 4 2 Coils Refer to Subsection 1 5 2 to correlate part numbers to coil resistance values The resistance selected depends on the system voltage and circuitry 1 4 3 Contacts Contacts of PN 150BM relays are heavy duty with silver to silver impregnated carbon fronts a
27. hat might adhere to the cleaning strips from cleaning the silver impregnated carbon contacts 4 2 1 2 Contacts That Are 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 several times if necessary e Using the Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or equal 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 steps f several times if necessary 4 2 1 3 Contacts with Heavy Tarnish Slightly Rough or Pitted a Perform the procedure in Subsection 4 2 1 2 Steps b to g 4 2 1 4 Contacts with Surface Film or Oxidation Not Pitted a Perform the procedure in Subsection 4 2 1 2 Steps f and g 4 2 4551 M 07 00 4 2 2 ARMATURE STOP PIN CONDITION The following instructions are for cleaning the armature stop pin See Figure 4 1 This procedure should be followed wherever a relay is shopped for failure to meet its calibration specifications during scheduled field inspection and tests STOP PIN SAFETY PINS See Enlarged Area
28. ing Subsection 4 5 5 them 4 4 1 Recommended Tools TABLE 4 2 RECOMMENDED REPAIR AND REPLACEMENT TOOLS Twist Drill 42 Screw Driver Torque Measuring 4 4 2 Disassembly Dismantle the relay only to the degree necessary to complete repairs Refer to the Appendix A Parts List for part information and location In general to dismantle the plug in relay proceed with the following sequence a Remove relay cover seal b Carefully remove plastic cover G Remove disassemble relav components as required d Remove contacts contact block as required e Remove permanent magnet as required NOTE These magnets are of a special allov that permits retention of proper strength indefinitelv if not abused When not in place on relavs magnet assemblies should be kept separated from other magnetic objects The screws that hold the extension to the magnet should be kept tight If a magnet becomes weakened it should be returned to the factorv for recharging bv special equipment required to fullv charge the magnet It will then be aged to its best working strength 4 4 3 Reassemblv Reassembly is accomplished generally in the reverse order of disassembly Do not overtighten or force parts when reassembling a relay The following paragraphs provide additional instructions to be followed during reassembly of this relay Upon completion of reassembly calibrate the relay as directed in Section 4 6 4 4 4551 M 0 00 4
29. lay contact cleaning using the following recommended cleaning materials 4 2 1 Cleaning Relay Contacts This section covers recommended methods for the preparation and cleaning of relay contacts TABLE 4 1 RECOMMENDED CLEANING MATERIALS Recommended Cleaning Materials Burnishing Tool P K Neuses Co No 3 316 J397187 Burnishing Tool P K Neuses Co No N318 Heavy Duty J397187 001 Paper Strip strips cut from 67 pound white Springhill Vellum Bristol Paper 4793094 Also recommended commercially available Emery Paper Wet or Dry 600 Grit cut in strips Alcohol 1 Solvent Ethyl Alcohol Proprietary 190 or equal NOTE When using the paper strip clean the back contacts first then the front contacts last Discard the paper strips when dirty 4551 M 09 00 4 1 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL 4 2 1 1 General a Preliminary information The cleaning tool should be used to clean no more than 12 front carbon and 12 back silver contacts after which it should be washed before re use The cleaning tool should be cleaned using a mild soap or detergent and water rinsing thoroughly and allowing to dry NOTE In the final cleaning procedures outlined in the following sections it is recommended that all silver contacts are cleaned first and then all silver impregnated carbon contacts This will ensure that the silver tips are not contaminated with residue t
30. n obtaining proper calibration it is permissible to vary the adjustments given in the foregoing paragraphs However a With the armature in its fully released position the front contacts must be open at least 0 050 inch When a front contact is just making the corresponding back contacts must be open more than 0 020 inch 4 6 CALIBRATION 4 6 1 Recommended Test Equipment Nomenclature Power Supply 0 40 Vdc Digital Multimeter two required DPDT double pole double throw S1 SPST Switch 2 4 6 2 Calibration Procedure Connect the circuit as shown in Figure 4 4 and proceed as follows a b 4 10 Set ammeter to appropriate current range Set voltmeter to appropriate voltage range Set DC power supply to appropriate output range Set switch S1 to Normal Turn DC power supply on and close S2 The relay shall first be energized at the Charge value specified in Table 4 7 or 4 8 with Switch S1 in the Reverse position under which condition the armature must not pick up The relay shall then be pole changed several times ending in the Normal position under which condition the armature shall pick up From the Charge value the voltage shall be gradually reduced until the armature drops away to open all front contacts This is the Drop Away value and it shall not be less than the minimum value specified in Table 4 7 or 4 8 The voltage shall then be further gradually reduce
31. nd silver to silver backs 1 5 SPECIFICATIONS The following paragraphs provide the electrical and mechanical specifications of the PN 150BM relays covered in this manual 1 5 1 Mechanical The following mechanical specifications are common to all PN 150BM relays covered in this manual TABLE 1 1 MECHANICAL SPECIFICATIONS Relay Dimensions Height 7 1 16 17 93 cm Width 2 7 16 6 19 cm Depth 8 3 8 21 27 cm Temperature 40 F 40 C to 185 F 85 C Indexing Refer to Section 2 3 Weight 6 75 16 3 06 kg Mounting Base N376048 old style for relays N322517 XXX N399689 old style for relays N322524 XXX N432995 old style for relays N322525 XXX N451376 0305 improved style for all above Mounting Base Weight 17 5 oz old style 9 5 oz improved style Mounting Base Height 7 15 16 20 16 cm Dimensions Width 2 7 16 6 19 cm Depth 2 7 16 6 19 cm old style Depth 1 25 32 4 52 cm improved style 152 4551 M 09 00 1 5 2 Electrical TABLE 1 2 RELAY ELECTRICAL SPECIFICATIONS Front Testing Ohms Amps Volts Voltage N322517 003 2F Mag HD 400 0 01475 58 N322517 004 2F l Nazaszi00t 27 28 Meg HD 0025 60 16 46 8322524 002 26 28 Meg HD 400 0 0174 T0 N322525 001 3F Mag H D 240 0 025 60 1046 N322525 002 3 Mag H D 2400 0 0174 7 0 N322525 004 3F Mag H D
32. of a compass needle which points toward geographic South The permanent magnet assembly should be applied to the relay as shown in Figure 4 2 making sure that the 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 4551 M 09 00 4 5 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL 4 5 ADJUSTMENTS All adjusting and testing must be done with the relay in its normal operating position 4 5 1 Recommended Tools and Test Equipment TABLE 4 3 RECOMMENDED ADJUSTMENT TOOLS AND TEST EQUIPMENT Item Part Number Gap Gauge 0 001 in to 0 250 in Gram Gauge 250 Grams Bending Tools J397164 0022 0023 0025 0026 4 5 2 Permanent Magnet Extension The permanent magnet extension should be adjusted so that it touches the two stop pins on the bottom of the armature with the nominal spacer specified in Test 1 Table 4 5 or 4 6 inserted and held firmly between the armature main stop pin and the upper pole face If necessary in order to obtain calibration values or contact openings this spacer may be varied within the limits given in Table 4 5 or 4 6 4 5 3 Permanent Magnet With the armature released both back stop pins should make contact with the permanent magnet ex
33. pecifications eec nun 1 3 1 3 Contact Assignments gt __ 1 3 2 1 2 4 2 2 Polaritv 2 5 4 1 Recommended Cleaning Materials 4 1 4 2 Recommended Repair and Replacement Tools 4 4 4 3 Recommended Adjustment Tools and Test Equipment 4 6 4 4 Contact ResISEATICO i dati ote epe hte ee Ee usu 4 11 4 5 Adjustment and Calibration Summary For N322517 XXX and N322525 XXX PN 150BM 4 12 4 6 Adjustment and Calibration Summary for PN 150BM with 2F 2B Magnetic Heavy Duty Contacts 322524 4 13 4 7 Calibration Values for PN 150BM Relays with 2F Magnetic Heavy Duty Contacts N322517 XXX rna 4 14 4 8 Calibration Values for PN 150BM Relays with either 2F 2B or 3F Magnetic Heavy Duty Contacts N322524 XXX and 322525 4 14 ii 4551 M 09 00 UNION SWITCH amp SIGNAL TABLE OF CONTENTS List of Figures 2 1 Typical Plug In Relay and Mounting 2 3 2 2 Receptacle Contact Spring Installed 2 2 3 2 3 External Connections to Mounting 2 5 4 1 Armature Stop Pin
34. rce on bottom contact engaging pin Pie DE Emm permanent magnet after charge aucem applied 4551 M 09 00 4 13 SECTION 4 SHOP MAINTENANCE UNION SWITCH amp SIGNAL TABLE 4 7 CALIBRATION VALUES FOR PN 150BM RELAYS WITH 2F MAGNETIC HEAVY DUTY CONTACTS N322517 XXX Relay Charge Minimum Drop Full Drop Away Resis Away TABLE 4 8 CALIBRATION VALUES FOR PN 150BM RELAYS WITH EITHER 2F 2B OR MAGNETIC HEAVY DUTY CONTACTS N322524 XXX AND N322525 XXX Relay Charge Minimum Full Full Stroke Resis Drop Away Drop Away Ohms Amps Volts Amps Volts Amps Volts Amps Volts 240 0 0835 200 0 00782 188 0 00521 1 25 0 025 6 0 400 0 058 232 0 0054 12 16 0 0036 1 44 0 0175 7 0 1300 0 03 43 3 0 0031 4 06 0 0021 2 71 0 010 13 0 2730 0 0217 59 35 0 002 5 56 0 0014 3 7 0 0066 18 0 220 220 0 11 24 24 0 010 2 27 0 0069 1 52 0 037 8 2 4 14 4551 M 0 00 UNION SWITCH amp SIGNAL APPENDIX A PARTS LIST A 1 PARTS LIST FOR PN 150BM MAGNETIC HEAVY DUTY CONTACT RELAYS N322517 XXX N322524 XXX N322525 XXX SEE FIGURE A1 IMPORTANT NOTE Individual relay contacts are no longer available If contact replacements are necessary a molded block contact assembly containing a complete set of new contacts should be installed The old style screw amp wedge contacts if still in good condition may
35. roper and efficient operation of the PN 150BM 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 if necessary use a soft cloth to clean the exterior to remove any dirt or dust that may have collected A safe cleaning solution of alcohol and water or common laundry detergent may be used for removal of accumulated dirt grease etc 3 2 2 Service Requirements 3 2 2 1 General All vital relays must be inspected and tested at least every four 4 years The tests and inspections are to include pick up current drop away current timing of slow operating contact resistance 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 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 7 or 4 8 a Drop Away value D A falls below 67 of the value given b Full Drop Away value F D A falls below
36. tension face and neither should project over the edge of the permanent magnet In this position the air gap at the permanent magnet extension face should average 0 004 inch parallel and must not be less than 0 003 inch at any point This is the physical air gap from plated extension face to plated armature ADJUSTABLE SHUNT MAGNET MAGNETIC SHUNT POLE PIECE REFERENCE MAGNET EXTENSION DIMENSIONS PHOSPHOR BRONZE OR STEEL SCREW AS REQUIRED FIGURE 4 2 ASSEMBLY OF PERMANENT MAGNET 4 6 4551 M 0 00 4 5 4 Indicator Adjustment of the armature position indicator after calibration should be made so that the bottom of the red painted surface is 1 13 16 inches from the main body of the relay frame when the relay is deenergized Viewed from the front of the relay with cover applied the red indicator should be in full view with the armature in the deenergized position and should be hidden with the armature in the energized position see Figure 4 2 4 5 5 Contact Adjustment The fingers supporting the contact springs should be straight and approximately at right angles to the relay base The heavy front and back contacts should be adjusted by bending in front of the brace rather than adjacent to the contact block using a bending tool J397164 0022 The bending tool J397164 0023 for the heels should be applied between the rivets Because of the effect of the weight of the contact tips all checks of contact adjustment should
37. usting Front and Heel Contact Springs Using the Test No 2 values per Table 4 5 or 4 6 at the rear of this service manual hold a gauge of the proper value firmly at the main stop pin by energizing the relay Adjust the front contact springs so that light is just barely visible between the contact tips A 0 003 thinner spacer should allow the contacts to close Deenergize the relay and remove the gauge Remove the operating arm by slightly compressing the extreme front end of the heel springs and hold it clear from all heel springs Adjust the heel spring members so that there is the appropriate clearance Table 4 5 or 4 6 between the front contacts and the heel contact tips Replace the operating arm and work the armature by hand a few times to get the operating arm into its normal position When replacing the operating arm make certain that the same side is to the front as reversing the arm may change adjustments because of slight warpages and molding tolerances On later production arms the word front is molded on one side Reinsert the Test No 2 gauge used above energize the relay and readjust the front contact springs as before Check that the Test No 2 gauge allows the contacts to close Per Table 4 6 using the 3 Test maximum spacer held firmly between the magnet and the armature lower stop pins adjust the back contact springs so that light is just barely visible between the contact tips Check that the 4 Test minimum spa
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