F82 INVERTER SERVICE MANUAL 6137 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA PART NUMBER N CONTENTS PAGE

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1 F82 INVERTER PART NUMBER N SERVICE MANUAL 6137 CONTENTS SECTION I II III IV v VI, PAGE GENERAL INFORMATION INTRODUCTION DESCRIPTION SPECIFICATIONS 1 FUNCTIONAL DESCRIPTION FUNCTIONAL OPERATION CIRCUIT DESCRIPTION 2 INSTALLATION MOUNTING INSTRUCTIONS ELECTRICAL CONNECTIONS 4 MAINTENANCE FIELD MAINTENANCE SHOP MAINTENANCE MECHANICAL INSPECTION ELECTRICAL TESTING 5 APPLICATION 6 PARTS LIST 10 June, 1981 B-8/ UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./ SWISSVALE, PA PRINTED IN USA

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3 UNION SWITCH & SIGNAL ffi SECTION I GENERAL INFORMATION 1.1 Introduction This Service Manual describes the F-82 Inverter and provides instructions for installation and maintenance. 1.2 Description The F-82 Inverter is specifically designed for use in type "C" track circuit applications and is used to convert direct current into alternating current at high efficiency. Essentially, the circuit consists of a solid state astable multivibrator driving several stages of power amplification and a coupling transformer. 1.3 Specifications Electrical Characteristics Power Requirements: Normal Operation Voltage volts ac Current - 1 ampere, maximum Standby Operation Voltage - nominal 12-volt input, storage battery, or regulated power supply ( volts de) Current - 10 amperes maximum Power Output: Normal Operation Four, 5.5 volt R.M.S. sine amperes each secondary. Standby Operation Four, 5.5 volt R.M.S. square amperes each secondary. Reverse battery protection built-in Physical Characteristics Overall dimensions: Length, 12 inches Width, 10 3/4 inches Height, 6 inches Weight, 23 pounds (approximate) Operating Temperature -40 C C 6137, p. 1

4 ffi UNION SWITCH & SIGNAL 2.1 Functional Operation SECTION II FUNCTIONAL DESCRIPTION The F-82 Inverter is designed for use as a standby power supply or as a sole power source for type "C" track circuit equipment. During normal operation of the inverter, the "steering" relay is energized and it applies 120 volts as power to the primary winding of the transformer producing four 5.5 volt sinusoidal secondary outputs. During power failure or low line voltage the "steering" relay is de-energized, automatically removing the ac source from its intended primary winding and connecting the transistorized inverter circuit to the 12 volt ac standby source. The type "C" track circuit is an ac-dc circuit designed to detect the presence of a train. A de relay is connected across an ac power source (F-82 Inverter) which is connected to the rails. A track rectifier is also connected across the rails at the opposite end of the track circuit providing a half wave shunt across the track circuit relay coil. The rectified ac signal energizes the de relay. When a train occupies the track within the track circuit limits, it shunts the recifier and the result is a lower power ac wave applied to the de relay. This action causes the relay to become de-energized. 2.2 Circuit Description The circuit diagram for the F-82 Inverter is shown in Fig. 1. During normal operation when 120 volt ac power is present at the "AC Input" terminals, relay 1 is energized removing power from the inverter circuit and applying voltage to the 120 volt winding of the transformer producing four 5.5 volt R.M.S. sinusoidal outputs. When this voltage is not present, for example during a power failure, relay 1 becomes de-energized open circuiting the 120 volt winding of the transformer and connecting the 12 volt de back up source to the inverter. The inverter circuit is made up of an integrated circuit astable multivibrator IC1 whose frequency of oscillation is determined by C1 and R1. The complimentary outputs of this multivibrator are amplified through transistors Q1 and Q2 to supply the base drive to transistors Q3 and Q4 which are connected in a push pull arrangement with two windings of the power transformer, T1, to produce 10 volts peak to peak ac square waves at the four sets of output terminals. Capacitors C2 and C3 feed back the energy stored in the transformer windings to the base of Q3 and Q4 to prevent collector voltage transients from reaching levels that would damage the transistors. R 2 and D1 are used to keep the voltage on IC 1 to 12 volt de and D2 along with F1 provide reverse battery protection. 6137, p. 2

5 UNION SWITCH & SIGNAL ffi c 1.01 uf c 2.33 uf c 3.33 uf c 4.01 uf D1 IN5242 D2 IN3208 F 1 10 AMP. F 2 1 AMP. C1 IC1 C04047AE L N N voe C4 IN N6282 GND N6262 I R2 C2 C3 Fe A R 1 390K R 2 1K =---- R3 5.1K 120VAC R 4 5.1K INPUT <I R ohms RELAY 1 R ohms <I Figure 1, Circuit Diagram of the F-82 Inverter 3.1 Mounting Instructions SECTION III INSTALLATION The F-82 is designed for wall or shelf mounting using standard mounting hardware, and installation should be in a dry location. Mounting holes and their dimensions are shown in Figure 6. CAUTION Damage to the equipment may result if air circulation is impeded. DO NOT MOUNT the F-82 near a wall of other piece of equipment that would impede air circulation around the F , p. 3

6 m UNION SWITCH & SIGNAL 3.2 Electrical Connections {See Figure 2) It is recommended that a 4000 MFD capacitor, J be placed across the positive and negative terminals of the inverter to reduce ripple caused by battery charging devices or excessive lead resistance in battery lines. The battery must be in good condition and have a low internal resistance or rated output may not be obtained. The approximate voltages between output terminals are also shown on the nameplate for nominal input voltage and full load output current. When the inverter is operated at less than full load, the output voltages will be slightly higher than indicated on the nameplate. f 82 INVERTER UN SER. NO. INPUTS OUTPUTS 12VDC 115 VAC 5.5 UC 5.5 UC 5.5 UC 5.5 UC IO NZ Field Maintenance Figure 2, F-82 Inverter Nameplate SECTION IV MAINTENANCE In the event that a unit does not operate properly a few simple tests will pinpoint the source of trouble. a) Check the wiring to insure that all connections are made at the correct terminals as shown in Figure 2. Correct the wiring if necessary before proceeding. b) Measure the de voltage from the battery to see that it is of the correct polarity and within the operating range shown in Section , p. 4

7 UNION SWITCH & SIGNAL ffi c) If the inverter still will not start then remove the load and see if it operates with no load. If this is the case then the inverter is being overloaded and the load should be reduced. d) If at this point the inverter still will not start then remove the cover and check for an open fuse on the printed circuit board. Replace if necessary. If the inverter operates with no load but the fuse blows when the load is connected then the unit is overloaded and the load should be reduced. If the new fuse blows with no load on the inverter then the unit should be taken to a properly equipped shop facility for repair. 4.2 Shop Maintenance Introduction This shop level maintenance information is supplied for those users who desire to repair malfunctioning inverters themselves. It is assumed in this section that the required test equipment is available (a list of recommended equipment is given below) Recommended Test Equipment (or their equivalent): Power supply, 0-20 volts, 0-30 amps, E. c. Equip., Inc. Type Scope, Tektronics Type 502. Counter, Atec Model 5A35. Variac, volts, 0-10 Amps; General Radio Company Type W10MT3. 6 Ohm, 100 watt, ±10% tolerance resistor. 4.3 Mechanical Inspection Printed Circuit Boards Inspect for good soldered onnections and check to see that the component values agree with the parts list on page Final Assembly Inspect to see that the components are installed securely in their correct positions. The wiring should follow good wiring practice and agree with that on the wiring diagram shown on Figure 6. Insure that fuses Fl, F2 and relay 1 are securely mounted in their proper locations. 4.4 Electrical Testing The following procedure should be followed to check the electrical characteristics of the F-82 Inverter. 1. Connect jumpers from terminals 6 to 7, 8 to 9 and 10 to 11. (Refer to figure 3.) 6137, p. 5

8 EE) UNION SWITCH & SIGNAL 2. Connect a 6 ohm, 100 watt, 10% load resistor across terminals 5 to Connect 12± 0.1 volt de to the+ DC and - DC terminals. 4. Measure 40 ± 2 volt peak to peak across the 6 ohm load. 5. Connect a frequency counter across the 6 ohm load. Check that the frequency is 60 ± 6 Hz. 6. With the DC supply still connected and an oscilloscope probe across the 6 ohm load, apply ± 2 volts ac to the AC input terminals. Observe that the wave on the oscilloscope changes from a square wave to a sine wave. 7. Measure 56.5 ± 3 volts peak to peak across the 6 ohm load. F-SZ lnve-rte-r UN4S D.C. POWE-R SUPPLY COUNTE:5" Figure 3, Connections for Electrical Testing SECTION V APPLICATION Track circuit arrangements to determine track occupancy varies depending on track configuration and train movements. A typical arrangement with three separate track circuits controlled by one F-82 Inverter is shown in Figure , p. 6

9 UNION SWITCH & SIGNAL m SECTION VI Parts List F-82 Inverter P. c. Board (N ) Refer to Figure 6 for item number identification ITEM DESCRIPTION Cover Chassis Transformer Heat Sink XSTR-2N6282 PCB, F82 Inverter BRD, TERM. (12 Way) Tag (1) Tag (2) Tag ( 3) Tag (4) Tag (5). Tag (6) Tag (7) Tag ( 8) Tag (9) Tag (10) Tag (11) Tag (12) Term, PR. Insul. DM. Grip Ser, l/4-20x3/4 Stl. Hex. Wash., 1/4 Stl. Plain Wash., 1/4 Stl. Lock Ser, #10-32x3/4 Stl. Filh Nut, 1/4-20 Stl. Hex. Nut Nut Washer, 17/64x9/16 Cop. Spacer, 6-32x7/8 SCR, #6-32xl/2 Stl. Rd. Wash, t-6 Stl. Plain Wash, #6 Stl. Lock Ser, l/4-20xl/2 Stl. Rd. Insulator Ser, #8-32x3/4 Stl. Rd. Wash., #8 Stl. Plain Wash., #8, Stl. Lock Nut, #8-32 Stl. Hex. Channel, Rubber Wash., #10 Stl. Lock Nut, #10-32 Stl. Hex. Socket, XSTR Insulator, Mica SCR, #6-32x5/8 Stl. Rd. Term., PR. Insul. DM, Grip Nut, Insulated US&S PART NO. M R N M J N J J J J J J J J J J J J J J J J J J J M M J M J J J J J J J J J A J J J J J J J , p. 9

10 m UNION SWITCH & SIGNAL F-82 Inverter P. c. Board (N ) Refer to Figure 5 for item number identification ITEM Rl R2 R3 & R4 RS & R6 Cl C2 & C3 C4 ICl Ql & Q2 Dl Fl F2 Fl, F2 RLY 1 RLY 1 Ql & Q2 RLY 1 RLY l RLY 1 RLY 1 RLY l Ll DESCRIPTION 1/16 Copper Laminated (4x6-l/4) Resistor 390K, 1/2 W Resistor lk, 1/2 w Resistor 5.lK, 1/2 w Resistor 510 Ohm, 1/2 W Capacitor.01 MFD, loov Capacitor.33 MFD, SOV Capacitor.01 MFD, looov Integrated Circuit CMOS CD4047 Transistor 2N3569 Diode - Zener 1N5242 Diode - 1N3208 Washer, 1/4 STL. Lock Nut, 1/4-28 STL. HEX Fuse - 10 Amp Fuse - 1 Amp Clip, Fuse Relay 3PDT, 120V Socket, Rly. PCB Transistor, Mtg. Pad Spring - Rly Hold Down Washer, #6 PL Washer, #6 Lock Nut, #6-32 HEX Screw, #6-32x RD. STL. Coil US&S PART NO. A J J J J J J J J J J J J J J J J J J J J J J J J N I P 10

11 UNION SWITCH & SIGNAL r 0, +12 OUT ().J F1 ' R6 A (2 ro AC OUT to ll2 \K 018 Cl.o,,...i 12 voe. IN Fl a LI A to»4p ot INSZO& C v Q'ZC GRD. T UT AC INPUi F2 1,\MP RL '< 1. g 1'20 V AC. OUi FIGURE 5, F-82 CIRCUIT BOARD COMPONENT LOCATION AND CIRCUIT DIAGRAM 6137, p. 11/12

12 + R WT l ;I; XT ( [ 1 "' l ET R UNION SWITCH & SIGNAL ffi Rt $t+j! + G)l I@ ADJUSTMENT TABLE FOR MINIMUM D.C. BALLAS7.. SPARE 1 + " DC POWER SOURCE ES - Rx 120VAC 60HZ TR TR Rx-t-- F-82 INVERTER,]_) rj?),]> Minimum island length is maximum inner wheel base. Ground in accordance with A.A.R. manual 61 and drawing 1424C. All track leads to be minimum #10 AWG. - or larger whee required. Battery lead resistance should be less than. OS ohm. c;ontacts of relays.to be used.in A.A.R. typical circuit. 8090B for highway crossing control. LENGTH TRACK CIRCUIT 4000FT so MIN. D.C. BALLAST OHMS/M FT a.so TR AMPS MIN. Rt I DRY AT OHMS Es= 5.2 VOLT I ADJUSTMENT TABLE FOR MINIMUM D.C. BALLAST OF 3.0 OHHS/M IT. LENGTH TR AMPS TRACK Rt DRY AT CIRCUIT OHMS Es = 5. 2 VOL TS 3000FT so ADJUSTMENT TABLE FOR MINIMUM D.C. DJ\LLAST OF 5.0 OHMS/M FT. Rt= 4.5 OHM, Nl56683 Rx= 1.25 OHM, M438112, loow R = Style RC-1 Rectifier - UN TR= 1.0 OHM, 6FB L.V., PN-150BTR, UN , Energization 0.25 Ampere Style F-82 Inverter - UN Normal Power Supply - 60Hz, 120 Volts Commercial Power Standby Power Supply - 12 V.D.C. Input, 60Hz Output Inverter R,ail Impedance ""'0.20 Ohm/M Ft. at 0.36 P.F.l6,9. Min..sistance to Shunt Track Relay 0.06 Ohm Broken Rail Protection Table Based on 0.15 Ohm Total Lead Resistance (including Track Leads and Case Wiring). ; Arrestor UX Arrestor UN Arrestor N CAUTION Disconnect rectifier from. rails when.. elding leads to the rails, or when welding rails to?revent possible equipment damage 1! LENGTH TR A.MPS TRACK Rt DRY AT CIRCUIT OHMS Es = 5. 2 VOLTS 4000FT so Figure 4, Type "C" Track Circuit Typical Application for Highway Crossing Control I P 7/8

13 1(_ _'--- (SK. L( ,_ s 102. I- I 1 0 N 11? E E3 I 1=4 A. \JS.I: ITf:M {41) FOR ALL 01"1-!E-i;I! 1"1:s:i,;(. POSTS, WIRING DIAGRAM SK.) A'Z. ('.I -lei> ' e. Q1.. VIE:-W ",A:' SI-IOWING LOCATION OF TE-MlNAI.S OF XTR, 50c:l( -TS(BoTTOM SIDE:) F Rev. 4 Figure 6, F-82 INVERTER PHYSICAL:DIMENSIONS AND WIRING DIAGRAM 6137, p. 13/14

Style FR HI Shunt Track Unit

I UNION SWITCH & SIGNALlimt 645 Russell Street Batesburg, SC 29006 Service Manual 5966 Style FR HI Shunt Track Unit Installation, Operation and Maintenance July, 1980 1980, Union Switch & Signal Inc. Printed