~ SERVICE SPECIFICATION SU-4583 ~

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1 .. WABCO SERVCE SPECFCATON SU-4583 STYLE F-50 NVERTER FOLLOWER UN General This service specification covers the testing and maintenance procedures for the Style F-50 nverter Follower. The F-50 functions as an amplifier for a low power signal from a driver or another F-50. t provides the in-phase feed for track circuits or another F-50 and is used in conjunction with the AC Phase Selective Unit. The F-50 is essentially three inverters in a single package. One inverter, operating continuously, supplies base drive for two separate power inverters: Local Power, for Phase Selective Units, and Pilot Line Power, to operate additional inverter-followers. The two output stages are controlled through a single code transmitter contact and supply tract circuit power. 2. General Equipment Specification A. nput Voltages 16 VDC (filtered) 16 VDC@4A maximum (filtered) Across terminals +16 and -16. Across terminals +16R and -16R. For front end drive. PRNTED N U.S.A. Bl UNON SWTCH & SGNAL DVSON Westinghouse Air Brake Company PTTSBURGH, PA April, 1967

2 WABCO NOTE For test purposes,. a 16V battery may be used. n this case, both 16V inputs are operated in multiple. f an F-60 power supply is employed, use specified terminals. n either case,ripple fed to the +16, -16 terminals should not exceed 0.1%. Maximum power requirement will not exceed 25A. Also note, the open circuit voltage of the F-60 will be approximately 19. 4V. High Level Signal.., 1 "'. ( V, 80 to llohz* square wave applied through a 75 ohm resistor.) NOTE: Resistor not required when operating from Pilot Line. Across terminals X and 2X with jumpers across 3X and 4X. Low Level Signal (nominal 18V, 80-llOHZ, O. 05 watt maximum square wave) Across terminals X and 4X. No jumper across 3X and 4X. B. Output Voltages Voltage 8. 5V ::1: A maximum Location Each track secondary from termin'als A to E. CAUTON Maximum continuous output must not exceed 228 VA total of all secondaries). OOV ::1: A maximum Local - terminals L+ and L- NOTE The llov tap, 3L, taped, not terminated. 115V ::1: 4A maximum (P and 3P) Pilot - terminals P, 2P and 3P. The P and 2P terminals are used when a 55V output is required. HERTZ* - cycles/sec. Definition adopted by EEE on Oct. 14, i965. SU-4583, p. 2

3 WABCO C. Overload Protection Output Track Outputs Pilot Line (P and 3P) Local terminals '(L- and L-) Terminals +16R and -16R Protection Each pair is fused at 20A on the primary side of the transformer. Also, the track circuits are fed through suitable resistors to limit the short circuit current to 17 A or less. Protected by line resistance of 425 ohms minimum (75 ohms in P lead, 250 ohms in 2X lead, and 100 ohms across X and 3X). Refer to schematic. Fused for O. 5A. Fused for 5A. D. Transient Protection Location nput and case and nputs and Outputs +DC and -DC terminals nput circuit Output circuit Protection Designed to withstand 3000 V AC for one minute. Diode prevents a reverse polarity application. Also suppresses inductive transients that may occur if inverter is energized from a battery line. Protected against surges by the line ballast. Diodes Dl through D9 protect against switching transients. E. Temperature Range The operating range is -30 F to 160 F. SU-4583, p. 3

4 WABCCJ 3. Maintenance A. Transistors All the Transistors used in the nverter Follower can be replaced without removing the cover or disconnecting leads attached to the main terminal board. The transistors used in the two output stages (Q5 through Q12) are mounted on the main hinged heat sink and are accessible by removing two screws and folding the heat sink outward on its hinge. There are two sections identified as follows: "Sl" - (hinge side) controls outputs la through le and 2A through 2E. Transistors Q5, Q6, Q9 and QlO, along with Resistors R4, R5, R8 and R9, are mounted on this section. Power to this section is controlled through Fuse Fl and "negative disconnect" attached to terminal #10.,.,,s2 11 controls outputs 3A through 3E and 4A through 4E. Transistors Q7, Q8, Qll and Q12, along with Resistors R6, R7, RO and Rll, are mounted on this section. Power to this section is controlled through Fuse F2 and "negative disconnect" attached to terminal #10. To remove either Sl or 82 sections, first break the "negative disconnect", then break the connectors #1 through 9. Remove the four ''hold down" nuts. The connecting surface must be protected when handling and coated with silicone grease before re-assembly. The transistors are plug connected for convenient removal. See Figure 4 for transistor terminal identification. The input transistors (Ql through Q4) and related components, are mounted on a removable board accessible through the opening under the hinged main heat sink. To remove this board, first disconnect the 8 pin plug connector and then remove the four hold-down nuts. See Figure 1 and Figure 6 for pin location of plug connector. This section is protected through fuse F3. See Figure 4 for transistor terminal identification. B. Transformers Transformers T3 through T7 can not be replaced without disconnecting leads attached to the main terminal board and removing the cover. See Figure. Transformers Tl and T2 are mounted on a component board and may be replaced in the field. See Figure 1 and the sixth paragraph under item 3A. SU-4583, p. 4

5 WABCO X - ), ,.J., """ "1... l.. : -- rs.. "" :'; -.. t_-- '.: :i L ' 4X 4X +16 REG 2 +16R o-l.. F3 -t6ro _j F4 41 L 3 L NOTE. C t,2 2 SEE VEW "A.. 2F F ) c 4P T3 F4 T4 45 ::l 18 F6 F5 Fl 3P 2P T6 C 10 E H '] "i 28 P - - Pl F2 NOTE A 6 P P 2C 20 2E 4P 45 3P 38 3C P 3E F2 48 4C 40 P 4E TS T7 +16 VEW"A" r------, A y / / F5 { r«>tes A. -16 VOLT CONNECTONS TO THESE TRANSSTORS ARE MADE TO THE HEAT SNK WTH WRE #10 STRANDED. B. 0- SYMBOL NDCATES CONNECTON TO TERMNAL BOARD. 2F F L J ON EARLY UNTS,F5 AND F6 N-LNE FUSES MOUNTED EXTERNALLY AND WRED PER SYSTEM cmcurrs. C. 3L LEAD OF Tl TO HAVE CONNECTOR UMl78714 (CROWS FOOT) ATTACHED FOR POSSBLE CONNECtlON TO TERM. 80. THS LEAD TO BE NSULATED WHEN NOT CALLED FOR. O. RESSTORS ARE N OHMS. CAPACTORS ARE N MCROFARAOS. NOTE DSREGARD NUMBERS ON MOLDED PLUG CONNECTORS R 120-3W R2 27-W :: } 27-W RS R6 R7 150-W RRS} 9 1-sw RO R Rl W Rl3-OO 25W Rl W Q Q2 t 2N2270 Q3 Q4 Q5 \. 2N 545A Q6 Q7 ::}- QO Q Ql2 MP502A 6 6 L+ L- P 3P 4PT5 ll'ts t OS PT& 06 3PT6 4PT4 03 O- 3PT7 PT PT7 c± 09 D A 09 N3331-A N368-HR i o-16 Oil 0152 A DO. c oov c c oov Fl - 20A - 32V CAUTON F2-20A - 32V F3 - SA - 32V SLOW BLOW NCORRECT POLARTY APPLED F4 - A - 250V SLOW BLOW TO TERMNALS WLL F5 - A V SHORT CRCUT POWER SUPPLY F6 - A - 250V AND BLOW F2 FUSE N POWER SUPPLY UNT UN Figure 1. Schematic Diagram SU-4583, p. 5/6

6 WABCCJ L 52..,L 11 S J Fl 22v F2 ;.zv F3 s;;.:v F4 O.$;;sv FS '!Av FG ;;sov , L Fl F2 F3 F4 ZOA-UV 20A-32V 5A-32Y 0.5A 32V SAG 000 5AG SAG SAG,(;\ \Y..._ t FUSE ARRANGEMENT ON EARLY UNTS. * APPEARS ONLY OH EARLY MOOELS. Figure 2. nverter Follower, Top View SU-4583, p. 7

7 WABCO N m... Figure 3. nverter Follower, nterior View SU-4583, p. 8

8 WAECC --ct_ T0-3 c (CASE) T0-36 T0-5 Figure 4. Transistor Base Diagrams SU-4583, p. 9

9 WABCO C. Test Data (1) High Level nput (No DC power applied) -"' a. Remove jumper across 3X and 4X. b. Apply 120V, 80-llOHZ square wave to terminals X and 2X through a 75 ohm, 25 watt resistor. The voltage across X and 3X should be 28. 2V ± 12% (true RMS) and the current O. 283A ± 12%. c. f values in step b fall beyond tolerance indicated, measure the values of Rl3, Rl4, Cl and C2. They should be within 10% tolerance. d. Place a jumper across 3X and 4X (note that base power is being applied to Q and Q2). The voltage across R should read between 1. 7V and 2. 3V D. C. (2) Front End Drive Test a. Apply 16 VDC (filtered) to the +16R and -16R terminals, with input, per above paragraph, through an external. 5A fuse to protect against improper phasing of transistor or transformer leads. Readings should be as follows: de B of Q3 and Q4 B of Q5 through Q8 L+, L-, OCV P - 3P, OCV P - 2P, OCV 0. 2A ± 10% A ± 10% (2V ± 10%) (measure voltage across R2 and R3 with a calibrated scope. Base current is peak of half-wave square wave) A ± 10% (3V ± 10%) (measure voltage across R4 through R7 with a calibrated scope. Base current is peak of half-wave square wave). 103 ± 5% (true RMS) ± 5% (true RMS) ± 5% (true RMS) b. Remove 0. 5A fuse. c. Load the L+ and L- output to 0. A and the P and 3P terminals to 0. 4A. The input current should not exceed 4. 5A with 16 VDC input (filtered). The actual value will vary with component tolerances, but should not be less than 3. SA. (3) Output Section Test Test the output sections separately with the Local and Pilot outputs unloaded. SU-4583, p. 10

10 a. Energize the front end as per item 1, this paragraph. b. Apply 16 VDC to +16R anq -16R (filtered 5A maximum). c. Jumper lf and +16 terminals to energize the T6 transformer. Meaure voltage across RS and R9 with a calibrated scope. The B of Q9 and QlO should be 1. 5A ± 20% (base current is peak of half-wave square wave) de should be 2. 5A ± 10%. The OC terminals voltage of each output section of T6 should be as listed below with a tolerance of 1 %. Terminal WABCC A to B A to C A to D A to E 2.4V) 4. 8V) Symmetrical square wave with 7. 8V) approximately 2V overshoot 9. OV) at leading edge. d. Remove jumper. e. Jumper 2F to +16 to energize the T7 transformer. Measure voltage across RO and Rll with a calibrated scope. The B of Qll and Q12 should be 1. 5A ± 20% (base current is peak of half-wave square wave). de should be 2. 5A ± 10%. The OC terminal voltage of each output section of T7 should correspond to those of T6 with the same tolerance of 1%. f. Remove jumper. (4) Load Test Power Supply UN is designed to operate the F-50 and may be used for this test. Due to heat sink limitations, the outputs of transformers T6 and T7 must be loaded and test separately. Proceed as follows: a. To simplify the load test, join the secondaries in series, i.e., for T6, join le and 2A and apply the load across la and 2E. For T7, join 3E and 4A and apply the load across 3A and 4E. b. Load each secondary to 17A (1 ohm approximately). c. Load Local and Pilot lines as previously explained. d. Energize front end as per previous tests. e. Apply 16 VDC to +16R and -16R (filtered 5A maximum). Ripple should be not more than 5%. f. Apply 16 VDC to +16 and -16 (filtered 25A maximum). Ripple should be not more than 0. 1% (not coded). g. Energize T6 by jumping lf to +16. To energize T7, jumper 2F to Each output section under field load will have output voltages as follows, ± 1% tolerance. Output A to B A to C A to D A to E 2.32V) 4. 64V) Symmetrical square 7. 54V) wave. Values 20 C. 8.7 V) SU-4583, p. 11

11 WAS CC (5) Transient Protection Check-Out - Dl through D9 n order to perform the following tests, all transistors must be operable. Proceed as follows:. a. De-energize front end, unload all curcuits, and remove all DC power. b. Check fuses Fl and F2 for continuity. c. Apply 16 VDC through a 0. 5A fuse to the +16 and -16 terminals, observing correct polarity. f the fuse opens, D9 is shorted and must be replaced; otherwise, the de will be less than 6 ma. d. To check Zener voltage, D9 must be removed from circuit. The value should be 50V ±5%. e. Disconnect diode DlO. Remove fuses Fl and F2 and apply 16 VDC through a 0. 5A fuse as follows: +power to the anode of D9; -power to the +16 terminal. The de should be Oat this point. f. Replace Fl. f the O. 5A fuse opens, either D5 or D6 is shorted. Otherwise, the de will be less than 6 ma. g. Replace F2. f the 0. 5A fuse opens, either D7 or D8 is shorted. Otherwise, the de will be less than 6 ma. h. Change the -power lead to the F terminal. f the 0. 5A fuse opens, either D3 or D4 is shorted. Otherwise, the de will be less than 6 ma. i.. Change the -power lead to the 2F terminal. f the 0. 5A fuse opens, either Dl or D2 is shorted. Otherwise, the de will be less than 6 ma. j. Reconnect DlO. SU-4583, p. 12

12 WABCC TERMNAL NO _...-t ""1 (NEGATVE DSCONNECT CONNECTON} NOTE: WHEN MOUNTED N UNT, S S NVERTED WTH RESPECT TO S2. S2 AS SHOWN S ( HNGED SDE) AS SHOWN N PARENTHESES ,---'--'---'-- 1$(2$),3S(3S)y 4S(4S1f2(FS2(S4l, T3(T3) T5(T4) T5(T4) T3(T3) Figure 5. Views of Heatsink SU-4583, p. 13

13 WAS CC C2 NO''ll Disregard numbers on molded plug connectors.. 4P 3P 2P P T2 4S 3S Figure 6. Component View SU-4583, p. 14

14 WABCO 4. Parts List Reference Designation Cl C2 Dl through D8 D9 DlO Fl, F2 F3 F4 F5, F6 Ql or Q2 Q3 through Q8 Q9 through 'Q12 Rl R2 and R3 R4 through R7 RS through Rll Rl2 R13 R14 Tl T2 T3 T4, T5 T6, T7 TEE-Section Component Board Part Number UJ UJ UJ UJ UJ UJ UJ UJ UJ UJ710102* UJ UJ UJ UJ UJ UJ UJ UJ UJ UJ UN UN UN UN UN UN UN Description Capacitor,. 022 Mfd. Capacitor, 01 Mfd. Diodes, D5 2S 1N3331A 368-HR Fuse, 20A - 5AG Fuse, 5A - 5AG (SLOW BLOW) Fuse, 0. 5A - 5AG (SLOW BLOW) Fuse, A - 3AG Fuse, A - 5AG 2N2270 2N1545A MP502A Resistor, 120 ohms - 3W Resistor, 27 ohms - 1 W Resistor, 150 ohm - lw Resistor, 1 ohm - 5W Resistor, 75 ohm - 25W Resistor, 100 ohms - low Resistor, 250 ohms - 25W nput Transformer Driver Transformer Driver and Power Transformer Driver Transformer Output Transformer Removable heat sink Complete with components *Original units furnished on N. Y., N. H. and H. R.R. used UJ in-line fuse. SU-4583, p. 15/16

15 ,r-:,.,

16 WABCO TAP:; END CF LEAD S & S2 6 NOTE DSREGARD NUMBERS ON MOLDED PLUG CONNECTORS.Q 2 3SE y... - N "l,t o... f tqu,'i' :! \l)t f t,...,...,......,...,... seee s... N al to'., TB-L+ 16 F4 'T.3-L 2 ;;=;--=---1TB2-4 i., V1 W SHCW1N(i Wl/1NG ENO OF Ptu(i Co,JHECro (Pl. Uj7o6 768) 0 TJf,;_6 2 FZ TB2-4,.#JO. Fl Tl;2 2. ' Q Q"'c>''!?''Q".Q.,.Q o o.. o.- lo 11.-,.-,.- 8 SS 8 es 3 g 2 ' <!!!,Jo1&1<t11VO... 1!";-;-t':'c;-t iiit0iiioiiouiaiil<iiiii t-. t-... 'Q"'/"o.. -0' "o 'Q' 'ii '?' o o,:.. '"' '!": -- t! e e ee t :=:!*: t f t - iii iii iii iii iii iii t-... t-. t-. J <o co oo : -: x )( >C......, -... iii iil iii...._.t- 1 /lfmnal. Pc. No. SYM,So L QTY..J:>wi.. l sh. 50LOE1' CoNN ct,oh 0 SE UMl18714 &24+,..., U17.30l SA 0 2 U.1'730 ll 804'4.,7SA 8 UT73Z9S 5 u so1o4ls75 TElfMJNAL SCHEDUl.t!. TE, T7 * COMPONENT LEAO & z VJ' eo"4 -'7S CXJ TWSTEO PAR. t :f: e J.731ZO,o cjj73z89 C:::l 4- uj10(o781 JCOl\lo.,l!.C."TOV,. CL T 2 A,'.J A \x, 3 JA.x.J.. 5.J. 1., 7.J.AA.J _. u 2 mm 11 "' Q) 7.- "'. N tn '!- m E ii... '\.o TAPE END OF LEAD Wtfi!. EQ1.M.EME.NT.5 10 BLACK FLl!.1< - VA4SOZ _. 16 Bt..AC( FLEX - UA 4-SOZ4 "'18 Bt..AC.( F1..e:x- l)a.450z & A?'PL"T 1'" LE.1'>G,n-1 a;e 11.!><.,._,,we,, UA""l<' 4-\ els 0'-lE."1. AL'- i' E\._, 'Tet."''"'AL.':> Figure 7. Wiring Diagram (Early Units) SU-4583, p. 17 /18

17 WABCO TB St && S2 1 '2 Q- Q..-,.=-.- :.,.- ;-.- 1!... Q,! O).,.O ri ";' '"' ' U i,,, i ' C9 U "':' ; l!: ll), 0, :=:, +,--..,_..,,...,-,r..,...,-...,-.. N -«:,, P- t 1 1(\lll 1 {\f 1rf\l"\l1 l f'l,0 e t!, ' e e C, y '-..; ;;- '.- ; ',-, A "' ([)... v D en di \fl t) ;;:.. ) ll' dl ('\ ;. '.: ti g: ::; t :::. ;;.,(j 1 -;- ' ': ,, 'i '-Lldl J- _, t-- }-.: t- t- l.l.._. t- t tioy Y Y Y Y 'ryvy A t- \- f- 0 Y "ryyy Y Y YYYY r. \.., l t 7 f',,-, 1 ' t!..,!. 1 ;...,!_ r-,. i:q \() \.0 cj Q'.) 3 fl)! :i..j..j _:!..!,:! ':!.. t-"',t-.., Lo ;..,,t-. - )-....t-. J- """.ti!4 _ll ctj... _n. ll a: Q..a...o. 1-: ll. " :; VtE.W l!nd (PL/ SHCtN1N WtR.1N(; OF PLV(i ':ona/ecto.. uj7o66b) ' TB1-2F FG. r5-2.p& '3P'."19 'l Till-F,lc1S1f,O -{T4 2.P&.3P r,;1-l 16 TB3 1 2 F4.,,a,r. TBl tl' TBJ F'3 16,o re FZ. "'10., TEMNAL :5CHEDJL!. 5YM80L qtt. SOLOl!lt CONNCTOr, lfrllmna.. Pc. No. l>wci- SH, 0 57 UMl18714 z44-,.., - :,;. '20 u:r 1.30 n, / UJ730 Sol.4!J1SA 8 U.T7.3J s J730O 80lo4 S75A * CoN1POAJl!NT LEAD (fl 2 V So'-4!J7G oo TWl$TEO PAR.i)_ t 8 VJ731Z!JO - -.i)_ * 10 vj73tzj!3 - - (:::j 4 UJ70Co781 C<>N,.e,c. TO'Z C) () 33 (JJ7300' o'"'!l 'o" 'o 'Q' 'a 'o' o o.- Q,,,- " ecevee 1 f T t r,_..,..,. "'-,-..-..,,,-. 'N',...,-..,:;{! t t t t aiiicollliigg i TB2. 4 "JO Fl.TB2-Z 2..,o Wt/Z JieEQUiR.EME.NT.5...,o BLACJ( FL.ax - LJA4S02. # 16 SL.ACK FLl'lX - UA -fsoz4 "'18 SLACK FLl!X- 1.)14 4S'OZ T6 T7 *'..., *' NO CONNECTON ZL -.. { TflPE ND Or LEl'JD.,;r 3P Q.... "! Te2 : - 3e -,_,.., ; u..i. " l w z -: '" L JC -,:,, ii Xl....- H z. co Q) 7.- "'. N Lil =, J-.,,o. T83 &_ sz-< ) 1 V!EWR TER/111/NF#TON VEW OF T4 a: rs 05 WRE /V/flRXERS VJ SH./2 (!VlflRKtN<i fls SPECtr/ 0 PER nos L)WG.) &?'l>ly 1"t.E.>.1G.T-\ 01<" '5H1>.1><.,v'<!, >JC.. UA-Y"14-lelS O'-'l!i. ""'-'- '! 8o.-" "' e_y\l>.a..s Figure 7 A. Wiring Diagram SU-4583, p. 19/20

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

An American-Standard Company.. SERVCE MANUAL 5799 (Not STYLE F-40A DC/DC CONVERTER MANTENANCE NSTRUCTONS Suitable for Outdoor Mounting) * * * * * * * * * * * (N451033-0801) Description The Style F-40A