5 1997 4596-X Service Manual PN-lSON Batesburg, SC 29006 I~ · ii UNION SWITCH & SIGNAL 8 REVlSION lNDEX This service manual supersedes all previously issued 4596-X ~nuals, and has

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... IUNIC)N SWITCH & SIGNAL I~ 645 E.ussell Street Batesburg, SC 29006

.·June, 1984 , A~6/84-150:2634-1

© 1984, Union Switch & Signal Inc. Printed in U.S.A. •· .

Service Manual 4596-X

PN-lSON DC Neutral Vital Relay · {Second Generation)

Part Numbers: N322502-701, 702, 703

RFr:Fn 1r-l")

MAY 5 1997

An I ANSALDO! Affiliated Company

SERVICE MANUAL 4596-X

DC NE.UTRAL VITAL RELAY PN-150 N

(Second Generation)

Part Numbers

N322502- 1701 170217031

THIS MANUAL SUPERSEDES SM 4551-B DATED OCTOBER, 1982

June, 1984 ID 0390/DN0056C A-6/84-150/2634-l

IN USA

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC. I SWISSVALE, PA 15218

ii

UNION SWITCH & SIGNAL 8 REVlSION lNDEX

This service manual supersedes all previously issued 4596-X ~nuals, and has been reissued to provide new or corrected data.

als ... · ,!'uttire, ,:.evlsi.()ns to . it~~.~~; 1}\ta.~l~t~~r>, \

l / GENERAL lNFOOMAT!ON

1.1 1.2 1.3

INTRODUCTION DESCRIPTION SPECIFICATIONS

ii INSTALLATION

2.1 2.2 2.3 2.4 2.5

GENERAL. MJUNTING BASE. RELAY INDEXING RECEP'.IACLE CONTACT SPRINGS RELAY INSERTION.

111. FlELD MAl.NrENANCE

3.1 3.2

l NTRODUC TION PERl.ODlC PERFCRMANCE TEST.

IV. SHOP MAlNTENANCE •

4.1 4.2 4.3 4.4 4.5 4.6

INrBODUCTlON. CLEANING AND INSPECTION CHECK-OUT PROCEDURE REP Al RS AND REPLACEMENT • ADJUSTMENTS. CALIBRATION· •

APPENDIX A PARTS LIST

UNION SWITCH & SIGNAL

Contents

1

• 1 1 1

3

3 3 3 4 6

7/S

7/8 7/8

9

9 9

12 12 14 18

iii

SECTION I GENERAL INFORMATION

require response to energy of

UNION SWITCH & SIGNAL m

The design of the PN-150N relay conforms to all applicable AAR specifications.

1.2 DESCRIPTION

1.2.1 General

The PN150N is factory calibrated to operate across a wide environmental range. All noving parts are enclosed in a sturdy, transparent, dust and moisture resistant cover. To insure the relay is inserted in its proper mounting base, all relays have indexing pins. Relays lock securely in the plug-in position.

l.2.2 Coils

Coil resistances of PN-150N relays are (depending on part number) 25,100 or 240 ohms. Refer to paragraph 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-150N relay are standard low voltage silver-to-silver impregnated carbon front and silver-to-silver back. Refer to Figure Al (in the Appendix) for a pictorial representation of the contact assembly.

1.3 SPEClFJCATIONS

The following paragraphs provide the electrical and mechanical specifications of the neutral relays covered in this manual.

4596-X, P• 1 .. ~., ...

m UNION SWITCH & SIGNAL

1. 3 .1 Electrical

Relay electrical specifications are tabulated below:

N322S02-703 /N322502-702 N322502-701

6 FB Std. 6 FB Std. 6 FB Std.

25 100 240

0.0545 0 .0285 0.0191

1.36 2.85 4.6

* Normally used in series with another relay.

Contacts - standard low voltage silver to silver-impregnated carbon front and silver to silver back.

1.3.2 Mechanical

The following mechanical specifications are common to all PN-150N relays covered in this manual.

Dimensions:

Temperature:

Indexing:

Weight:

Mounting Base:

Mounting Base Weight:

Mounting Base Dimensions:

4596-X, p. 2

Reight Wiath Depth

7-1/16" (17.93 om) 2-7/16" (6.19 cm) 8-3/8" (21.27 cm)

Refer to Section 2.3

6.75 lbs. (3.068 kg)

N334266 (Old Style) N451376-0203 (Improved Style)

17.5 oz. (496.11 Grams) (Old Style) 9.5 oz. (269.32 Grams) (Improved Style)

Reight Width Depth Depth

7-15/16" (20.16 cm) 2-7/16" (6.19 cm) 2-7/16" (6.19 cm) (Old Style) 1-25/32" (4.52 cm) (1mpr<:>ved Style)

* * *

SECTION l.l INSTALLATION


2 .. l ~.-~

:·•·•,t,~(jj:;~~j}i~~~:~ij:1/~J~::~)~i~·µii~:.i~:~~{~·i~.~···•·· ;$··.,~qqr~a;:,fci· a. tifi:· ··.···~J .6~ir installation iristruetiona required are for the mount.ing base.

2.2 M:>UNTING 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 (receptacles contact springs).

Mounting base details are shown in Figures A-3 (Old Style Base) and A-4 (Improved Base) of the Appendix.

2.3 RELAY INDEXlNG

Relays are factory equipped with indexing pins to prevent insertion of an incorrect relay into a mounting base. Each relay is accompanied by an indexing plate which is applied to the mounting base at the time of initial installation. A typical plug-in relay with indexing pins and base with indexing plate is shown in Figure 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 nl.11lber and its suffix which is marked on the name plate attached to the front of the relay. The first two digits of the index code are the last two digits of the part number, and the second two digits of the index code are the last two digits of the suffix. The index nl.11lber thus obtained should· agree with the placement of the indexing pins in the numbered vertical rows on the back of the relay starting with the top pin and reading down.

c. The index code for each mounting base is determined by the placement of the holes in the numbered vertical rows of the large white nylon indexing plate which is affixed to the front of the mounting base. This indexing plate should not be renoved from the Jlk)unting base unless it is damaged or the indexing is to be purposely changed to accanmoda'l:e a relay of a different part number. Discard the indexing plate which comes in a bag tied to the handle of all new relays unless it is needed for replacement of damaged indexing plate or for application to a new mounting base.

4596-X, p. 3


WARNING

NEVER DRILL NEW HOLES IN A BASE INDEXING PLATE WHICH WILL PElf.1IT APPLlCATlON OF RELAYS WlTR DIFFERENT PART NUMBERS,

\:.>• ~ I ,, ·:>./1',\{~·~.'c;i{', . '•,, ·i:t1'\, ,~,· .:~\ .. /·,{<~:{\'./,:-:;

c1umGE 1Nt>sii'Ns ]?]_~fr aN '1lIB · BACK oF A RE~ ti~ss · iT

··~.-· lS BEING CONVERTED TO A NEW PART NUMBER. OTHEK'llSE, A HAZARD WlLL BE CREA'IED WHICH MAY COMPROMISE SAFETY CIRCUIT FUNCTIONS.

2 .4 ROCEPTACLE CONTACT SPRINGS

2. 4 .1 Old Style a·ase Only

The mounting base will normally be equipped with the required quantity of J680165 solderless receptacle contact springs, and will accommodate one or two il4 or il6 wires. lt can, however, be equipped with receptacle contact springs for one or two ilO or il2 wires (J680181), or for one or two il8 or #20 wires (J680179}. Make certain which type of solderless receptacle contact springs accompany the mounting base before proceeding with their installation.

2. 4. 2 lrnproved One Piece Base Only

The one piece mounting base with hardware (N451376-0302) includes a full complement of receptacle contact springs (J680195-0001) to accommodate one or two il4-il6 wires, mounting fasteners, and tags. lt can, however, be equipped with receptacle contact springs for one or two il0-il2 wires (J680195-0002), or for one or two #18-#20 (J680195). Make certain which type of solderless receptacles contact springs accompany the mounting base before proceeding with their installation.

Each solderless receptacle contact springs should be inspected for physical damc1.ge 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 with the lock side down (Refer to Figure 2).

b. Make certain that the lanced tab is slightly compr·essed as the receptacle contact spring is inserted along the top of the cavity.

c. After insertion, pull firmly on the wire to make certain the receptacle contact spring is locked in the receptacle.

4596-X, p. 4

UNION SWITCH & SIGNAL m INDEXING PINS

INDEX PLATE I.!)

Q::i :.:::,

~ &:?::>. ~ ~ ~ t:::, :.:::, !.:::,

MOUNTING BASE

Figure 1. Typical Plug-In Relay and Mounting Base

LOCK SIDE

OLD MOUNTING BASE NEW MOUNTING BASE

RECEPTACLE CONTACT SPRING

Figure 2. Receptacle Contact Spring Installed

4596-X, p. 5


2.4.3 lnstalling 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 i~entiJiQ~ :!:,he eorrei:::t- er ~ing toQl- to be u1;1~ w~~n. il}$ta,1Ung wir~ in 'r~~e~~~ ~q#t~~~.-~J#iijg~ •. ·' ·~ ·: ·,, ,, ·.t,':<:,:: . .'<·vJ;'::i

' -

/

Old Style Improved Base Crimoina Tool Receptacle Receptacle

(T&B Type} (Amp Type) Wire Size Contact Spring Contact Spring

J397138 il0/il2 AWG J680181 J680195-0002 J397139 U4/il6 AWG J680165 (Standard) J680195-0001

M451151-0503 il8/i20 AWG J680179 J680195

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 ja~s of the proper crimping tool.

c. Partially close the crimping tool jaws against the receptacle contact spring to hold it in place. (Do not crush the receptacle contact spring barrel at this time.)

d. lnsert 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.

2.5 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.

4596-X, p. 6

3.1 INTRODUCTION

SECTION III FIELD MAINTENANCE


•.·.·····\i:t(i:rttti~~i,i:w~~:,~~ir:t:i::~~,;~i~!i)p;;;;:!~l7!i:;;ne: .:;:::~~es ;f the PN·l5dN 'i:eiays'covered in 'this manual. Field maintenance covers periodic in~pections 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.l General

All vital relays must be inspected and tested at least every two (2) years. The tests and inspections are to include; pick-up current, drop-away current, timing of slow operating and timing relays; and visual inspection of contacts for damage or misalignment, corrosion or other contamination of parts, loose parts inside of the cover, broken seal, and cracked or broken cover.

All vital relays installed in locomotive or car-carried equipment are to be inspected and tested at least every two {2) years as above. In addition, every four years the relays are to be removed from service and adjusted, repaired and tested.

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&S specifications.

3.2.2.2 In-Service Test

It is recommended that line relays in service be removed from service for shop ~epairs when one or more of the following conditions occur: (Use as a reference the calibration values given in Table I or II.)

a. Drop-Away value (D.A.) falls below 67% of the value given.

b. Full-Drop-Away value (F.D.A.) falls below 33% of the value given.

c. Full Stro~e value (F.S.) increases to more than 110% of the value given.

3.2.2.3 Test Procedures

Test the operating charactei:istics of th,e PN-.lSON relays as given in paragraph 4.6 Calibration.

4596-X, p. 7 /8

4.1 lNTRODUCTlON

SECTION lV SROP MAINTENANCE

ittf ,.,·~~'~t~lt.- <:i;i~1~:~ttt~~~-·:· -shop for repair have bt!e~ 'checked in the field and have unacceptably or have been physically damaged.

4 .2 CLEANING AND lNSPEX::TlON

UNION SWITCH Bi SIGNAL m

··--·,·;ii~~t~l&~~#':;• to perform

Before inspecting the relay and initiating repairs, use a soft cloth to clean the exterior carefully to rem::>ve any dirt or dust that may have collected. A safe cleaning solution of alcohol and water or conunon laundry detergent may be used for renoval of accunulated 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 clean the surface between the armature and the pole faces, especially the stop pin area (see Figure 3), using a lint free cloth and alcohol.

Proceed with relay contact cleaning, using the following reconunended cleaning materials:

Recommended Cleaning Materials

Cleaning Tool Extra sleeving for recovering three metal tools #4/0 Metallographic paper sheet 9" x 14" Burnishing tool Distilled Water

4.2.1 Cleaning Relay Contacts

Order Reference

N378099 J772330 J035215 J397187

This section covers reconunended methods for the preparation and cleaning of relay contacts.

After contacts have been dressed and/or after adjustments have been made to meet calibration requirements, the contacts should be cleaned in accordance with the procedure given in paragraph 4.2.l.1 and 4.2.1.2. Due to the possible unavailability of the sleeving (J772330) for the Cleaning Tool (N378099), an alternate contact cleaning procedure is presented in paragraph 4.2.2.

4596-X, p. 9


,, -~ ~\)~~-::, :>:,y, . ,';; ,'. \\ \~::.~\./

CAUTlON

TRE FOLLOWING IS ONLY MANDATORY FOR CLFAR LEX.AN MOLDED DRlVlsRS. DEV .LATlON FBOM THlS PROCEDURE MAY RESULT IN

'"'~ ~~'(;:,)!~~t''~~~,'_>',,.;)f/ ~'}\ I ,//\{<~ ' ' ' ,,if.;)il!,'. JLtf1lijSllmU fQ ,OSJ: ' , "0£ SP~J'',,

co»TACTS, oi4L'i 'v1:R:ou.f F,, N •JF,, cAvAiiAai.E FROM J."-l'.1.,WiWl'i!""

STEPHENSON CREMlCAL CO. AS MS-180 OR MS-230 CONTACT RE-NJ FREON 'IF) lS APPROVED BY U.S.&S FOR CLEANING CONTACTS WlTH TRE DRIVER ATTACRED TO THE CONTACT SPRINGS.

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.

4596-X, p. 10

CONTACT DRIVER

Figure 3. Armature Stop Pin Location·

NOTE

In the final cleaning procedures outlined in the following sections, it is reconunended 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 strips from cleaning the silver impregnated carbon contacts.

UNION SWITCH & SIGNAL m b. New Sleeving

To apply new sleeving to the cleaning tool, heat seal one end by placing flame and pinching quickly with pliers. Stretch the sleeving over

· 1;~91 and QJJ'\;.qi:t'< ~lt ·· ;t!al:,.~f:~' ,~yop.t'i,,:t:.t1e.~c:1 9f .~he

.··.··.\f~l~'~it1ng ·'.t~lt~'}l~1~:·····.£i~i·: ~~~t,~i,~,:~;:;t~irt!ti·:~a~; .... · · .. 4.2.1.2 Contact Cleaning Procedure

a. Apply distilled water (dispensed from a clean closed container) to one end of a cleaning tool, and wash the active back contact tip members in one row of contacts while applying pressure by holding the armature. Wipe the contacts with at least six short strokes of the strip.

b. lmnediately after the washing, the contacts should be wiped dry second clean, lint-free cleaning tool. This "dry wipe" renoves loosens any residue, such as dust, which was left from step 'a'. the contacts with at least six short strokes of the tool.

using a or

Wipe

c. Apply more distilled water to the same end of the cleaning tool and wipe a second row of back contacts. Immediately wipe these contacts dry with the same end of the dry tool as was previously used.

d. Repeat step 'c' for each row of front contacts.

e. lnmediately blow the contacts with filtered low pressure compressed air 1x> r enove any loose dust.

f. The other ends of the washing and drying tools may be used for cleaning the contacts on one other relay. They should then be washed before re-use.

g. lf the contact resistance is still too high, burnish the contacts with metallographic paper cut in strips 1/2 inch wide and repeat steps 'a' to 'e' to remove the dust formed.

h. lf the contacts are burned or pitted and the operation per step 'g' does not successfully reduce the contact resistance, burnish the contacts in the direction of slide with burnishing tool J397187. Follow with metallographic paper and repeat steps 'a' to 'e' to renove the dust formed.

4.2.2 Cleaning Relay Contacts (Alternate)

Recommended Cleaning Materials

Burnishing Tool, P.K. Neuses Co. No. 3-316 Burnishing Tool, P.K. Neuses Co. No. N318 (Heavy Duty) Paper Strip, strips cut from 67 pound white

Springhill Vellum Bristol Paper

Also reconunended (commercially available) Emary Paper, Wet or Dry, 600 Grit, cut in strips Freon TF, Miller Stephenson MS180

J397187 J397187-001

J793094

4596-X, p. 11


NOTE

When using the paper strip, clean the back contacts first, then the front contacts last. Discard the

4.2.2.l Contacts That Are Severely Burned

a. Using a 600 grit emery paper strip folded with the grit side out so that both contacts can be burnished simultaneously, stroke the contacts in the direction of contact wipe.

b. Using the burnishing tool, stroke the contacts several times in the direction of contact wipe.

d. Place the paper strip between the open contacts, then close the contacts and withdraw the paper strip.

e. Repeat steps "d" several times if necessary.

f. Using the Freon TF spray, give the contacts a degreasing/wash.

g. Place the paper strip between the open contacts, then close the contacts and withdraw the paper strip.

h. Hepeat steps "g" several times if necessary.

4.2.2.2 Contacts With Heavy Tarnish, Slightly Rough or Pitted

a. Perform the procedure in paragraph 4.2.2.1, Steps "b" to "h".

4.2.2.3 Contacts With Surface Film or Oxidation (Not Pitted)

a. Perform the procedure in paragraph 4.2.2.1, Steps "g" and "h"

4.3 CHECK-OUT PROCEDURE (Performance Test)

Perform calibration in accordance with paragraph 4.6.

4. 4 REP Al RS 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 (Paragraph 4.2.1) and readjusting (paragraph 4.5.6) them.

4.4.1 Recommended Tools

Twist Drill - #42 Screw Driver - Torque Measuring

4596-X, p. 12

UNION SWITCH & SIGNAL ffi 4.4.2 Disassembly

Dismantle the relay only to the degree necessary to complete repairs. Refer to the parts list appendix for part information and location of parts. ln

/ b. Carefully remove plastic cover.

c. Renove/disassemble relay components as required.

d. Remove contacts/contact block as required.

4.4.3 Reassembly

Reassembly is accomplished generally in the reverse order not overtighten or force parts when reassembling a relay. paragraphs provide additional instructions to be followed this relay.

of disassembly. Do The following

during reassembly of

Upon completion of reassembly, calibrate the relay as directed in paragraph 4.6.

4.4.4 General Parts Replacement

4.4.4.l Replacing Contact Block

!f the contact block is to be replaced by another, remove the old block, then use a small punch to renove the small dowel pins. Attach the new block with the four screws. Torque the contact block screws to 10(,:t 2) inch pounds. Run a #42 drill (0.0935 Dia.) thru the dowel pin holes into the epoxy contact block tor 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 aluminum surface.

if it is 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.

Do not overtighten or force parts when reassembling a relay. Upon completion of reassembly, calibrate the relay as directed in paragraph 4.6.

4596-X, p. 13


4.5 ADJUSTMENTS

All adjusting and testing must be done with the relay in its normal operating position.

Gap Gauge - 0.001 in. to 0.200 in. Gram Gauge - 250 Grams Screw Driver - Torque Measuring Driver Renoval Tool Bending Tool

4. 5.2 Armature Air Gap

Part Number

Nl05440

N451151-2801 J397164-0039

'lhe armature air gap is the distance from armature to pole face, with the stop pin against the pole face. lt should not at any point be less than 0.026" minus .002". At the stop pin, light must not be visible across more than 25% of the diameter of the pin. Light must be visible between the hinge plate on the armature and the forward pole face. Safety stop pins should have minimum of 0.001 inch clearance when the armature is at full stroke.

4.5.3 Armature Hold-DJwn Latch

Assemble the hold-down latch and the washers into the bearing bracket on the armature and spread both prongs at each end of pin and lock by peening tightly around front oorner of the support.

Make sure that the latch is perfectly free on the pin and does not bind in any position.

4. 5.4 Armature Back Stop (See Figure 4)

Assemble the back stop, strap, screws and bolt locks to the pole piece, fastening the back stop securely near the mid-point of its allowable adjustment. Adjust the back stop by bending to just touch the bottom of the latch bearing bracket on both sides with a 0.120" spacer between the main stop pin and the pole piece. While doing this, be certain that the armature latch is not allowed to lock by placing a thin strip of paper or shim material between it and the locking surface of the back stop.

Remove the 0.120" spacer and the paper shim and adjust the back stop end wise until the latch locks against the back stop locking surface with a 0.017" to 0.019" spacer between the bottom of the armature and the back stop. Tighten the screws but do not lock them until after calibration.

4596-X, p. 14

UNION SWITCH & SIGNAL m With the main armature held against its back-stop and the relay energized sufficiently to pick up and hold the latch armature against its upper stop, adjust the latch stop so that the center of the engaging end of the latch armature is OJ?li>osite the top edge of the locking surface on the back stop.

, I~

Excessive latch stroke will cause it to have a low drop-away value.

CONT ACT DRIVER

BACK STOP

(LATCH ARMATURE)

-- HOLD DOWN LATCH

Figure 4. Assembly of Armature Back Stop

4. 5. 5 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-inch from the main body of the relay frame. Viewed from the front of the relay with cover applied, the indicator should be in full view with the armature in the deenergized position, and should be hidden with the armature in the energized position.

4.5.6 Contact Adjustment

Contact surfaces should not be disturbed unless there is evidence of severe pitting from excessive loading or an accidental short through the contacts. ln 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 requirements, clean the contacts in accordance with the instructions in paragraph 4.2 of this manual.

Preadjust the contacts with the contact block mounted on the relay frame if necessary, but do not set them to meet calibration. Best contact stability is obtained by slightly overbending the spring and returning it to the desired position.

4596-X, p. 15


4.5.6.1 Relays with Individual Contact Drivers

Adjustment Procedures

b. Align the fingers of the driver bracket with ea.ch other and with the armature.

NOTE

When adjusting contact springs, do not bend the heavy members (terminals).

c. Rough align the heel springs with each other and straighten, if necessary, to correct for bowed springs.

d. 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 clearance is greater than 0.010, discard the driver.

e. With the relay in its normal operating position, install the contact drivers and the driver clips loosely (to be removed later).

f. Insert the nominal Front Closed spacer (Table 1) over the st.op pin. With the relay energized, adjust the front contacts so that they are all just closed with little or no pressure (both contact tips should be touching, but light can be visible under one tip providing that both tips touch at full stroke.

g. Remove the spacer and insert the Back Closed spacer (Table I). With the relay energized, adjust the back contacts so that they are all closed with little or no pressure (both contact tips should be touching, but light can be visible under one tip providing that both tips touch at full stroke.

h. Replace the spacer with the Heel Contact spacer (Table 1) and check for free play between the heel spring and the driver slot.

i. Remove the driver clips and contact drivers. Adjust the heel springs by bending at the thin sections 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.

j. 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. lf necessary adjust the driver bracket.

k. Install the contact drivers and driver clips loosely. Mount the relay in its normal operating operation.

1. Using the nominal Front Closed spacer (Table 1), adjust the front contacts to just close.

4596-X, p. 16

UNION SWITCH & SIGNAL m m. Remove spacer and replace with the nominal Front Open spacer and

adjust the front contacts to just open.

p. Remove the driver clips and contact drivers. Adjust the heel springs so that there is 0.005 - 0.010 inches between the front and back contacts to the heel contacts.

q. Reinstall the contact drivers and driver clips and check the front and back contacts with the spacers called for in Table I.

r. 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 section of the bracket finger. The driver should be free of any binding in all armature positions.

NOTE

New driver clips must be installed any time that the drivers have been removed.

4.5.6.2 Relays With Molded Driver

a. Ensure that the contact block mounting screws are torqued to 10 .:!:. 2 inch pounds.

b. Check heel springs for bow and adjust as required.

c. With the relay in its normal operating position, place the nr:>lded contact driver in position on the relay.

d. Insert the nominal Front Closed spacer (Table 1) under the stop pin. With the relay energi'zed, adjust the front contacts so that they are all just closed with little or no pressure (both contact tips must be touching) •

e. Remove the spacer and insert the Back Closed spacer {Table 1). the relay energized, adjust the back contacts so that they are just closed with little or no pressure (both contact tips must touching).

With all be

f. Using TooL N451151-2801, 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.

g. Reinstall the driver on the relay.

4596-X, p. 17


h. Using the nominal Front Closed spacer (Table 1), adjust the front contacts to just close.

i. Replace the spacer with the nominal Front Open spacer and adjust the

k. Replace the spacer with the nominal Back Open spacer and adjust the back contacts to just open.

1. Repeat adjustment R to K until each contact is open on its respective "open" spacer and closed on its respective "closed" spacer.

m. Check for heel spring play.

NOTE

When the armature is held at mid-stroke with neither fronts or baOkS making, all heel springs should ideally rest flat against the bottan edge of the driver slot. For those relays which do not meet the above condition, there is a maximum clearance allowable between the bottan 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 bottan of a driver slot. Also, no heel spring is permitted to rub against the sides of the driver. 'l'he driver clip on the armature has slotted holes to allow the clip to be adjusted so that no rubbing is evident.

4.6 CALlBRATlON

4.6.1 Reconunended Test :Equipment

NCMENCI.ATURE

Power Sug;>ly, 0-40 Vck:: Digital Multimeter (Two required) Double Pole, Double Throw Switch (Sl)

PART/MODEL/fiPE NO.

HP6205 or equivalent HP3435 or equivalent

4 .6.2 Procedure. Connect the circuit as shown in Figure 5, and proceed as follows:

a. Set voltmeter and ammeter to their appropriate range and adjust the de power sug;>ly voltage to the "Charge" values given in Table 11.

4596-X, p. 18

UNION SWITCH & SIGNAL m b. With switch Sl set in normal position, increase the current to the

charge value and then gradually reduce until the armature drops away, opening all front contacts and closing all back contacts. This is the main armature minimQm drop-away value, and should not be less than the

· l;r·la~!l~I?:,~~ .~,~~~t~,t~\~~~~~~~~;~~~;: ·.· ··· away fr;an the latch !iltop. This is the latch armature minimum drop"-away and should not be less than the values given in Table 11.

d. Set switch Sl to reverse position. Gradually increase current until latch armature picks up. This is the latch armature maximum reverse pick-up and should not be greater than the values given in Table 11.

e. Continue to slowly increase current until the main armature picks up to full stroke. This is the maximum reverse working value and should not be greater than the values given in Table 11.

f. Set switch Sl to the normal position and continue to increase current to the charge value. Gradually reduce current to full drop-away. Momentarily open switch Sl and return it to the normal position, gradually increasing current to full-stroke. This value shall not be greater than the value read above in "e" for full stroke. This is the "normal" full stroke value obtained from the polarity at which the relay was charged.

g. Remove the leads to the pc»1er supply and connect them in reverse thereby reversing the polarity of the test circuit.

h. Repeat Step 'a' through 'f'.

i. The relay may be returned to service if it meets the calibration values of Table 11.

+ DC

POWER SUPPLY

AMMETER

51

VOLTMETER REVERSE

Figure 5. PN-150N Relay Test Circuit

-A

RELAY UNDER TEST

4596-X, p. 19


4.6.3 Hold Down Torque

With the relay in imfo1;>sil::)le to put

the normal upright position and deenergizect, it should be pressure against the armatttre {without damage to relay parts)

a~· i to iE~ll( .... ~ t;.he it the lat<::h /;:~\· ).~::,:_-·: --

4.~.4 Contact Resistance

Resistance of front contacts should be measured with the armature in its full-strQke position, and resistance of back cont~cts should be measured with the armature fully released. Cleaned contact resistance should not exceed the following values.

Silver to Silver-impregnated Carbon Silver to Silver

4596-X., p. 20

Ohms Ohms Front Contacts Back Contacts

0.09 0.18 0.03

,s:,. U1 ID 0\

~ .. tti . N ....

TABLE No. I

Adjustment and Calibration Values for PN-150N

Adjust using nominal spacers for test numbers 1-4 for all relays. These spacers may not be changed except when the does not rest on the back stop with the relay de-energized. The ~inimum spacer for adjusting the back contacts may

Test No.

1.

lA,

18.

2.

2A.

3.

4.

s.

6.

1.

8.

9.

10.

11.

12.

13.

Test

Back Stop

Back Stop

Latch Armature Adjustment

Front Contact Adjustment

Front Contact Adjustment

Back Contact Adjustment

Back Contact Compression Test

a-Front Contact Openings b-Front Contact Openings c-Front & Back Contact Openings

Drop-Away

Drop-Away of Latch Armature

Reverse P.U, of Latch Armature

Rev, P.U. of Arm Without Cover

(To close Front with Cover Contacts)

Reverse Working (To Stop Pin)

Opposite Polarity Checks

Hold-Down Force

Final Electrical Inspection

Nom. Min, Mcpt.

0.120 11 0.118" 0,122"

0.117" 0,115" 0.119

0.01811 0.017" 0,019"

0,031" 0.028" 0.034"

0.028 11 0.025 11 0.031 11

o. 034" 0.02811 0.034"

o. 031" 0.025" 0,031"

0.025" 0,050" 0,005"

Table 11

Table II

Table II

Table LI

-5% -5%

Table II

Table 11

Force about sufficient to buckle horiz. armatu~e springs.

Remarks

Main stop-pin spacer for adjustment, Armature touching backstop.

Main stop-pin spacer for checking aftj;ij: :: adjusting armature. ··· . .c·-''>>

Armature raised to lock latch, Spaeet-iL, between back stop and armature. ···

Main stop-pin spacer. Contacts just ,llJl~.~:o Main stop-pin. Contacts must close,

Back stop spacer. Contacts just open;./

Spacer between back stop and armature~: Contacts must close.

With Back Contacts just closed, Armature released against back stop. With operating arms removed,

After charge. To open front contacts, ~i(d' close back contacts. · "'·'·

After Drop-Away, reduce current until{l;~J:ith drops and locks, ·'.·

To allow pick-up of main armature.

Mark Actual Value on left s~de of aiOl}a};~te.

Permissible variation from Actual Pick-Up without cover,

Repeats tests 6-10 with opposite pol{lf.i,ti1i!:S,

Force on bottom of armature to open back contacts, Back must not open,

Recheck Test Nos, 6-11 with Cover awt:i.~,4,

c z 0 z I ::j 0 ::i:: IP f/1

ci z )> ...

EB


Calibration Values for with 6F-6B Low Voltage Contacts and with a 0.023" Parallel Air Gap

Relay Latch Armature Hain Armature Resis. Hain Armature Latch Armature Max. Reverse Max. Reverse

in .Chante Min. Droo-Awav Min. Dro ,-Awav Pick-u1> Workin2 ·-Ohms Amps. Volts Amps. Volts Amps Volts Amps~ Volts Amps. Volts

25 0.202 5.05 0.0179 0.448 0.0119 0.299 I 0.0374 0.935 o. )545 1.36

100 0,106 10.6 0.0094 0.94 0.0063 0.63 0.0196 1.96 0.0285 2.85

240 0,07 16,9 0,0063 1.5 0.0042 1.0 I 0.0130 3.12 i 0.0191 ! 4,6 I I !

4596-X, p. 22

sERv,ce MANUAL4ssa-x' Appendix A

Parts List

DC NEUTRAL VITAL RELAY PN-150 N

(Second Generation)

Part Numbers

Na22so2- I 101 I 102 j 1oa I

THIS MANUAL SUPERSEDES SM 4551-B DATED OCTOBER, 1982

June, 1984

ID 0390/DN0056C A-6/84-150-2634-l

; US~,

UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA 15218

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

PARTS LIST PN-150N RELAYS WITH INDIVIDUAL DRIVERS

(See Figure Al)

Frame, Relay Rod, Latch Pin Roll Deleted Latch Dowel Pin Spring Armature Screw Washer Block, Contact Screw, #6-32 x 3/4 Phillips Fil. Hd. Mach. TP Shim Block, Hinge Deleted Screw, #8-32 x 5/8 Hex. Stl. TP Armature, Stop Strap Was11er, Plate Screw, i/:8-32 x 1/2 Hex. Stl. T. Pl. Handle Washer, Lock #10 Int. Tooth Ph. B2. NP Screw, #10-32 x 3/8 Phillips Pan Hd. Stl. Cad. P. Coil (Relay N322502-701) Coil (Relay N322502-702) Coil (Relay N322502-703) Shim Shim Screw, 1/4-20 x 3/4 Hex. Cap. Stl. TP Screw, 4/:4 x 3/16 (z) Rd. Stl. Sh. Met. T. Pl Plate, Name Pin, Indexing Gasket Cover Deleted Deleted Screw Wire, Seal Seal Spring, Armature Tag, Calibration Wash, #6 Shprf. Int. Teeth


PART NUMBER

M433355 M388888 J487087

M321728 J048716 M321861 N451137-0901 M335156 M005511 N435531 J522168 M433358 126105-0401

J500076 M333712 M.333 711 M434609 J046369 J561111 J047710 J525277 N333975 N321647-003 N379650 M434091 M434092 J050016 J052674 M.437787 J487090 J047081 M335067

J522042-001 A043013 J079351 M.433411 S003665 J047713

4596-X, P• A-1


PARTS LIST (Cont'd.)

.-------.--------- - ---·-----------

, .e:t1'.6t1~~~:('.:~~i·{f~~r,~Ji:~sijlif8t>"· ,·Nll'·,•.:~N8~i'

41 41 42 43 44 45 46 47 48 49 so 51 52 53

4596-X, P• A-2

Parts Bag (Relay N322502-702) (Not Shown) Parts Bag (Relay N322502-703) (Not Shown) Deleted Lock, Bolt Latch Armature Washer Pin Tag, Instruction (Not Shown) Magnetic Shield Washer Screw, 1/:4-40 x 3/16 Rd. Stl. T. Pl. Contact Driver Driver Clip Seal, Vent

· f!t3;oJlli6~tW N330681-0202 N330681-0203

M.262770 N333718 M333713 M333708 8000456 M383051 M059612 J525024 M433043 M433404 J790257

FIIOW·A!-

cl)-+

SECTION "£·£ ,,

0000000000

0000000000

1/11' ~RI' 'iq ,.


Drawing D66000 Sh. 4A, Rev. 11

Figure Al. PN-150N Relay with Individual Driver

4596-X, p. A-3/4

2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

UNION SWITCH & SIGNAL (:13

PARTS LIST FOR PN-150N RELAYS WITH MOLDED DRIVERS (See Figure A2)

Ro~, Latch Pin Roll Deleted Latch Dowel Pin Spring Armature Screw Washer Block, Contact Screw, #6-32 x 3/4 Phillips Fil. Rd. Mach. TP Shim Block, Hinge Deleted Screw, #8-32 x 5/8 Hex. Stl. TP Armature, Stop Strap Washer, Plate Screw, #8-32 x 1/2 Hex. Stl. T. Pl. Handle Washer, Lock #10 Int. Tooth Ph. B2. NP Screw, *10-32 x 3/8 Phillips Pan Hd. Stl. Cad. p. Coil (Relay N322502-701) Coil (Relay N322502-702) Coil (Relay N322502-703) Shim Shim Screw, 1/4-20 x 3/4 Hex. Cap. Stl. TP Screw, #4 x 3/16 (z) Rd. Stl. Sh. Met. T. Pl Plate, Name Pin, Indexing Gasket Cover Spring, Operating Arm Washer, Plate Screw Wire, Seal Seal Spring, Armature Tag, Calibration · Wash, #6 Shprf. Int. Teeth

MJ'88888 J487087

M321728 J048716 M321861 N451137-1401 M335156 M005511 N438691 J522168 M433358 J26105-0401

J500076 M333712 M333711 J475199 J046369 J561111 J047710 J525277 N333975 N321647-003 N379650 M434091 M434092 J050016 J052674 M437787 J487090 J047081 M335067 M349785 M335733-001 J522042-001 A043013 J079351 M433411 8003665 J047713

4596-X, p. A-5

ffi UNION SWITCH & SIGNAL

PARTS LIST (Cont'd.)

·.· ' ' .. ois.~ni>uobt ~~~~~~~~~:~·/~:-'~~:.;,i,;;,I;;,,;is4,;::,rb4;':;if~it;: t~~i . Shown) .

41 Parts Bag (Relay N322502-702) (Not Shown) 41 Parts Bag (Relay N322502-703) (Not Shown) 42 Lock, Bolt 43 Lock, Bolt 44 Latch Armature 45 Washer 46 Pin 47 Tag, Instruction (Not Shown) 48 Magnetic Shield 49 Washer 50 Screw, #4-40 x 3/16 Rd. Stl. T. Pl. 51 Screw, #6-32 x 1/4 Hex. Hd. Stl. 52 Arm, Operating 53 Seal, Vent

4596-X, p. A-6

. Jfiiibf-i~ti N330681-0202 N330681-0203 M275388 J792919 N333718 M333713 M333708 8000456 M383051 M059612 J525024 J463075 M373632-001 J790257

T I

ROW·Af!!-

co-

2

5I£CT!ON "E·E'

-----

0000000000

0000000000


"~~ E)

ll9_ ___ = ~----- _____ alz -~--

@ @

@

~ \

• T

/J

Drawing D66000 Sh. 4B, Rev. 5

Figure A2. . h ~olded Drivers PN-150N Relay wit

4596-X, P· A-?/B

1a

lb

le

2 3

4

5 6 7 8 9

10 11 12 13 14 15 16 16 16 17 18

NOTE II A:

J680179

J680165

J680181

J078455 J078458

J078459

M321745 J075828 J052674 J052667 J047775 J047501 J048002 J047711 J052246 M267499 J522090 M322078-0101 M322078-0102 M322078-0104 N322965 J077931

PARTS LIST FOR OLD MOUNTING BASE (See Figure A3)

UNION SWITCH 8t SIGNAL m

R$tieptacle Contact Spring, Solderless Type ;'118 to #20 Wire Receptacle Contact Spring, Solderless Type #14 to #16 Wire Receptacle Contact Spring, Solderless Type 110 to #12 Wire Base, Basic Mounting Plate, Contact Clamping (Order should specify part number of mounting base for which contact clamping plate is desired) Plate, Contact Clamping (Order should specify part number of mounting base for which contact clampfng plate is desired) Strike Tag Screw 14 x 3/16 Rd. Hd. Screw, 1/4-20 x 1-1/4 Rd. Hd. (Not shown) Washer, Lock (Not shown) Washer, 1/4 Stl. Plate Nut, 1/4 (Not shown) Washer (Not shown) Screw #6-32 x 1-1/4 Fil. Hd. s. Maoh. Nut Screw #6-32 x 5/8 Fil. Hd. s. Mach. Indexing Plate (Relay N322502-701) Indexing Plate (Relay N322502-702) Indexing Plate (Relay N322502-703) Meter Test Plug Insulated Test Plug (For opening any coil or contact circuit for removing receptacle springs)

When munting ba~e complete is ordered a bag of parts is included in the inner carton with the mounting base and instruction prints.

Bag Contains: Tags (Item 6), Screws (Item 7), and Items 8, 9, 10, and 12 which are used for attaching the munting base to the rack.

Included Also are: (Required Quantity) Receptacle contact springs (solderless) J680165 for 114 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 ).

4596-X, p. A-9


.... a o a a a a a a . . . -++++tt-+

;f :jf l~f lj!q;,i; . .. ~-+-a-a ~ -- .........---..-w..--.. a e e

• ...

.... ...

...-~~~~~~~~~~-~~~~~~~~~~~ ...

IQ -

..... !?

[][] =· ., . CT>CD CD CD tlbll

9 0 iO c& • .. Q

.. + • .... .. Q .. -

CU CD CD CD CD CD0

c• .. .. . .. a .. -I~ ebfJ CTJ tJJ CO CD ett· 0 Q ..... .. .. z .... c i

...

Figure A3. Old Style Mounting Base for PN-150N Relays

4596-X, p. A-10

/1c 2 3' 4 5 6 7 8 9

10 11 12

NOTE "A:

, N45 f 20301 N451376-0303 J780055 J792848 J4?0;?8Q J6so:19s-0001 J052667 J047775 J047501 J048002 J075951 soooooa J078399

Bag Contains:

PARTS LIST FOR IMPROVED MOUNTING BASE (See Figure A4)

El~e Only


Base Complete for Car Carrying Relays (Note "A") Base, Mounting Molded Strike-Relay ijid~"".$peed Push-:-On Recep tacie Contact Spring Screw, 1/4-20 x 1-1/4 Rd. Washer, 1/4 Stl. Lk. Med. Washer, 1/4 Stl. Plate Nut, 1/4-20 UNC-28 Hvy. Tag, Relay Indent. Sheet, Instr. Form #8 Bag, Plastic

When mounting base complete is ordered a plastic bag of parts is included in the inner carton with the mounting base and instruction prints.

Tags (Item 10), Sorews (Item 6) Items 6, 7, 8 and 9 which are used for attaching the mounting base to the rack.

Included receptacle contact springs are normally (J680195-0001) for #14 and 1/:16 wire, unless otherwise specified. If other wire size is used, the proper part ruimber (J680195 for #18-20; J680194-0002 for #10-12) should be specified when ordering the complete base (N451376-0302 except using receptacle contact springs, solderless J680195-0002).

4596-X, p. A-11

ffi UNION SWITCH & SIGNAL

~~:..+1----~~M~~t ~

.. ~, ,. ~ i------------- sL------------- s 1------------- !! l ---------------i ,.,

Figure A4. Improved Mounting Base for PP-150N Relays

4596-X, p. A-12 ·'.'.·

Documents

5 1997 4596-X Service Manual PN-lSON Batesburg, SC 29006 I~ · ii UNION SWITCH & SIGNAL 8 REVlSION lNDEX This service manual supersedes all previously issued 4596-X ~nuals, and has