STYLE F-40A DC/DC CONVERTER MAINTENANCE INSTRUCTIONS Suitable for Outdoor Mounting) * * * * * * * * * * * (N )

Transcription

1 An American-Standard Company.. SERVCE MANUAL 5799 (Not STYLE F-40A DC/DC CONVERTER MANTENANCE NSTRUCTONS Suitable for Outdoor Mounting) * * * * * * * * * * * (N ) Description The Style F-40A converter is a completely transistorized d-c to d-c converter developed for general use as a power supply unit in train control systems. t is also intended to replace the motor generator sets currently used in existing train control installations. The F-40A converter consists essentially of an electronically controlled pre-regulator and an inverter with rectified and filtered outputs.aschematic diagram of the converter is shown in Figure 1. The unit is designed to operate continuously in an ambient temperature of -30 to +140 F. Excursions to -40F will not damage the equipment. Electrical connections are made to a terminal board mounted behind a standard junction box plate on the front side of the converter. The input and output cables use a common "cable connector" which is located along side the junction box cover. The converter displaces approximately 1 cu. ft. and can be mounted either horizontally or vertically on 7-3/4" x 10" centers with 3/8'' bolts. For details see outline diagram, Figure 2. nput and output circuits are completely isolated from each other and ground. February, 1979 B UNON SWTCH & SGNAL DVSON WESTNGHOUSE AR BRAKE COMPANY Swissvale, PA 15218

2 WABCO ~ Operating Characteristics: nput Voltage: 55 to 80 V. D. C. Output Voltage: A. -12 V. D. C. ±5% at Oto 6A load referred to common, over the full ambient range (including -12Vunfiltered when used.) B. +12 V. D. c. ±5% at Oto 2A load referred to common, over the full ambient range. C. +12 V. D. C. unfiltered, ±5% at Oto 3A load referred to common, over the full ambient range. D. 100 V. D. c. ±10% at Oto O. la load referred to common, over the full ambient range. The converter is designed to start under full load with input voltages of from 55 to 80 V. D. C. A sustained drop in input voltage to 45V, after the converter is operating, will not damage the unit. Ripple -12V output +12V output loov output +12V auxiliary output Filtered Outputs 15 mv. peak to peak 25 mv. peak to peak 1 v peak to peak unfiltered Overload Protection The -12V output is not fused but is self-protected. A short circuit across this winding will "stop" the magnetic oscillator and can remain shorted indefinitely without dam ange to the unit. To restart after a short circuit has been removed, open the input circuit and then reclose after a few seconds delay. The +12V filtered output is not self protected against short circuits but is provided with 3A fuse. The +12V unfiltered output is-not fused but is self-protected in a manner similar to the -12V output. 5799, p. 2

3 The 100 V. D. C. output is not self protected against short circuits,but is provided with a 0.15 A fuse. A 43V ±5% zener diode is provided across the pre-regulator output (2000 µf -50V capacitor, C6) to protect against a malfunction of the input circuit. This zener diode will conduct on over-voltage and prevents high voltage being applied to the outputs. A 7-1/2 A input fuse is provided. Transient Voltage The converter input is designed to withstand a surge voltage of 1250 V for 300 to 400 microseconds, line to line and a 3000 V. A. C. dielectric test between input or output terminals and the case, for a period of 1 minute. A diode is placed across the input circuit to prevent a reverse polarity application and also to suppress inductive transients that occur on the battery line when the battery is disconnected. Calibration At room temperature (30 C), with 72 V. D. C. applied to the input terminals, adjust the -12V output by means of potentiometer (R24), located on a panel Just inside the cover, to read exactly 12V with the following resistive loads applied: -12V +12V +12V loov 3.0A LOA O. OA (unfiltered voltage) O. loa Lock R24 in its calibrated position. Maintenance Maintenance should consist of an occasional check of the output voltages. f voltages do not fall within specified limits, refer to the calibration paragraphs above. Units that can not be brought into specifications should be returned to the factory for repairs. 5799, p. a,,'4

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5 WABCD '-/'~ STYLE F-40A DC/DC CONVERTER Parts List ORDER BY PECE NUMBER & DESCRPTON SHOWN N BOLD TYPE tem Piece Used No. Description No. On CAPACTORS Cl 01 mfd., 600V UJ C mfd., 150V UJ C3 250 mfd., 6V UJ C4 250 mfd., 150V UJ C5 40 mfd., 150V UJ C mfd., 50V UJ cs 47 mfd., 200V UJ C9 8 mfd., 50V UJ ClO 100 mfd., 50V UJ Cll 6000 mfd., 15V UJ Cl mfd., 15V UJ Cl mfd., 15V UJ Cl mfd., 15V UJ Cl mfd., 50V UJ Cl mfd., 50V UJ DODES Diode Rectifier Bridge UJ Dl Diode, 1N972B UJ D2 Diode, 0152 UJ D4 Diode, 0152 UJ D5 Diode, 0152 UJ D6 Diode, 1N2993B UJ D7 Diode, 368D UJ D8 Diode, 368DR UJ D9 Diode, 368HR UJ , p. 5

6 WABCC ~ ORDER BY PECE NUMBER & DESCRPTON SHOWN N BOLD TYPE tem No. Piece Used Description No. On DODES (cont) DlO Dll Dl2 Dl3 Dl4 Dl5 Dl6 Dl9 D20 Diode, 368 HR Diode, 368 H Diode, 368 H Diode, 368 D Diode, D52 Diode, Z4XL14 B Diode, 0152 Diode, 0152 Diode, 0152 UJ UJ UJ UJ UJ UJ UJ UJ UJ FUSES Fl F2 F3 Fuse, 15A, 250V Fuse, 7-1/2 A, 32V_ Fuse, 3A, 32V UJ UJ UJ COLS L L2 L3 L4 Coil Coil, 18 mh Coil Coil UN UN UN UN Q Q2 Q3 Q4 Q5 Q6 Q7 QB Q9 QO Qll Ql2 Ql3 Ql4 Ql5 TRANSSTORS Transistor, 2N2270 Transistor, 2N2716 Transistor, 2N2716 Transistor, 2N2716 Transistor, DTG2400 Transistor, DTG2400 Transistor, MCR1305-4, SCR Transistor, 2Nl545 Transistor; 2Nl545 Traµsistor, 2Nl545 Transistor, 2Nl545 Transistor, 2N2270 Transistor, 2N2270 Transistor, 2N3055 Transistor, 2N2156 UJ UJ UJ UJ UJ UJ UJ72395l UJ UJ UJ UJ UJ UJ U:J UJ , p. 6

7 WABCD "V'~ ORDER BY PECE NUMBER & DESCRPTON SHOWN N BOLD TYPE tem Piece Used No. Description No. On RESSTORS R OK, W UJ R2 2.2K, W UJ R3 680 ohms, 2W UJ R4 100 ohms, lw, thermistor UJ R5 160 ohms, lw UJ R6 22K, W UJ R7 K, 2W UJ RS 51 ohms, lw UJ R9 180 ohms, lw UJ RO 22K, W UJ Rll OK, W UJ Rl2 1. 5K, W UJ Rl4 100 ohms, W UJ Rl5 82 ohms, low UJ Rl6 100 ohms, 2W UJ Rl7 200 ohms, 3W UJ Rl8 330 ohms, 2W UJ Rl9 K, W UJ R20 5 ohms, low, fusable resistor UJ R ohms, 5W UJ72344 R22 OK, 2W UJ72913 R23 K, 2W UJ R ohms, 2W, potentiometer UJ62250 R26 lok, 2W UJ72913 R27 25 ohms, 2W UJ R ohms, lw UJ R ohms, lw UJ R ohms, lw UJ R ohms, W UJ R32 15 ohms, W UJ R K, W UJ R K, W UJ R35 OK, 2W UJ72913 R36 22K, W UJ R ohms, 2W UJ R ohms, 2W UJ R ohms, W UJ TRANSFORMERS Tl Transformer UN T2 Transformer :UN p. 7/8

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9 WABCO ~ ± OOVOC NPUT NOMN\L 12voc UN = OW FUS BLE RES STOA C V ~$~ P4 JN tt,14003 r 6 +35v REG 2.m,-- 40(9150 '"VJ- F2 HOV OK 1c 'J.cz i o,, ~.,, (3680)::: ~ 2j 200V 150V Jl00t15 a:: i01 L l,r (SUD) R,1ooz19, l 2. VVY 2KQZ :: 2N271-0 L "r.. N " N "' ~!! : ---- = : :N; = 020 D 1N400J 1N972 ~ l Cl. - ~ "' - OK 1' 6~~v ltl4so~~- 121) N "' 11 : l C6+11 5J 2000 $0V 06 N 5361 A REMOVED FROM Cl- DURNG CONVERTER OUTPUT TEST. r QO 2N 545 #14 RED WRE TO BE... ltl o ,- -,NJ ltl & N4003 D 6 N4003 ~t: s~~:.,..5k :~~ "' Ql2 12 L 8,i ~ 12.~ i! :.: NOTE: CAPAC TORS - Mf'O } RESSTORS _ W UNLESS - NDCATES STANDOFF TURRET - NDCATES CRCUT BOARD CONH CTON OR COMPONENT TERM HAL * - CONvERTOR OUTPUT TEST PONTS V DC UNFLTERED STYLE F40A DC-.!)(;_ J;_OOERTER 1001 UN BO UL ll g ;: -..., -c:.,. -, -.-,......;-.. :- CRCUT DAGRNol Cl' POER SUPPLES : Jiii:'.);. :.t,.~. ~~~) : ~a.: ~ ~=*i~~a~ai2aj~' ~/ - =~t::. :~:: :. cooc:..:,oawr,.tt'99u,t- -NHYLY-tA1a11U11A h~-~~~~~~~~~~~~.~.~~~-~~~~,~-~~~~~~~~~~-~.~.r~~~~~---.~2-----~~~~ ~~;~--~~,---~- QQC 'v... r-\l'i-'2.. ijrjcnooll\lc\ 1~. w-~~~~m,~~~~ ~..,,&.~ w11: T1N0ttou -...,.,.NCl:COM,._ " -.,.,;. Kb ;:;, ~;. '~. : 8 :l::~.. ~2~2a:!;;;ff -"- M-- m " \,.;.;.. ~ n ti C-. l!!z!... t!-n~-~--"" "'1TTS~~-n.v"'"!'A,1St1 GA.ff!.z -~- -"""'.,." Figure 1. Style F40A DC/DC Converter Circuit Diagram 5799, p. 9/10

10 WABCCJ ~ i.-.~~~~~~~~~~~1si M~A_X_ ~~~~~~~~--'-i END BELL RE.TA N/NG SCREWS ('=>) c ~~ ) c ), :s..: V-?k AMP - 250V AMP FUSE L. FUSE.,, COVER. RETANNG SCREWS (<o)... 0 MAX. 9..9i6 r-~~~~~~~~~~~~~~~~~=== termnal COVER.' T l -~~~~~AL 5CR v.js (4) + 0 MTG.DM, --. k- 23 MTG. 32. SL.OT,9! MAX. ~ 3 - COtvOUT 4 CONNECTOR j 1 MTC:,. 1,.--16 SL.OT /0 MTG. DtM. NPUT OUTPUT TERMNALS \ NOTES :- ACCESS TO FUSES S OSTAl,-JE.O 8Y REMOv NCi COVE..R RETA1N1NG SCRE:W.S Ap..JD L.F'Til'JG COVER STRA1~HT UP. ACCESS To TERMNALS FOi< 11\JPJT A ND OUTPUT W1R1N4 S OSTA NED BY Ul'JSC.REwlN(i CAPTVE COVER SC.REWS A ND REMOV N(i. TERM NA.L. COVER. Figure 2. Assembly Diagram 5799 p. 11/12

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12 WABCCJ An American-Standard Company UNON SWTCH & SGNAL DVSON WESTNGHOUSE AR BRAKE COMPANY Swissvale, PA 15218