SERVICE MANUAL 6097 Operation, Installation and Maintenance UNTUNED DECODING UNITS and DECODING TRANSFORMERS for EL Coded Cab Signal Equipment January, 1978 A-09/86 30-2176-3 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./PITISBURGH, PA 15237 PRINTED.N vsa COPYRIGHT 1986, US&S DIVISION OF AMERICAN STA.NDARD INC.
SERVICE MANUAL 6097 Operation, Installation and Main~enance UNTUNED DECODING UNITS and DECODING TRANSFORMERS for EL Coded Cab Signal Equipment J~nuary, 1978 A-09/86-30-2176-3 UNION SWITCH & SIGNAL DIVISION AMERICAN STANDARD INC./PITISBURGH, PA 15237 PRINTED.N usa COPYRIGHT 1986, US&S DIVISION OF AMERICAN STANDARD INC
CONTENTS Section I II III IV v VI GENERAL DESCRIPTION ASSEMBLY AND WIRING MECHANICAL INSPECTION ELECTRICAL INSPECTION DETAIL PARTS SPECIFICATION ORDERING REFERENCES A. Wiring Diagrams for Decoding Units B. Wiring Diagrams for Decoding Transformers 1 3 4 4 7 11 11 11 J
I. GENERAL DESCRIPTION ' There are two types of untuned decoding units used with type EL cab signal equipment, including the Decoding Transformer Unit and the Tuned Decoding unit. The Decoding Transformer unit is used to operate the Tuned Decoding Unit (may or may not be provided with relay output}, and also to provide a decoding relay that will be energized on all code frequencies. These units are identical in outside appearance, but the only common parts are a decoding transformer and a capacitor for suppressing arcing on the master relay contacts. In addition to these, the Decoding Units include a reactor and a silicon rectifier assembly for supplying de energy to the coils of the associated decoding relay, and a test jack for measuring the relay current. The Decoding Transformer Unit includes (in addition to the transformer and capacitor) a resistor which is connected in series with the pirmary of the transformer. The Decoding Transformer is attached to its mounting bracket by steel bands. Other components are also mounted on this bracket, which is attached to the bottom of the case by four screws. When a test jack is used, it is attached to the front of the case. Attached to the outside of the case are a handle, a plug connector guide bars for engaging bars on the equipment box shelf (for proper alignment of plug connector), and the name plate. Each unit bears it own serial number stencilled on the name plate. See Figures 1 and 2 for interior views of the Decoding Unit and Decoding Transformer Unit, respectively. TEST JACK RECTIFIER ASSEMBLY Figure 1. Decoding Unit 6097, p. 1
The Untuned Decoding Units are similar in outside appearance to the Tuned D~coding Units (refer to Service Manual 6096) and use the same plug connector. However, on the Untuned Decoding Units, this plug connector is rotated 180 degrees from the position used on the Tuned Decoding Units. With this arrangement, the indexing hole in the plug connector socket does not match with the indexing pin on the plug connector in the space for the Tuned Decoding units. This makas it impossible to plug an untuned unit into a space intended for a tuned unit. The Untuned Decoding Unit may be distinguished from the Tuned Decoding Unit by the name plate designation. Figure 2. Decoding Transformer Unit 6097, p. 2
II. ASSEMBLY AND WIRING If it should become necessary to dismantle the decoding unit for repair, the transformer mounting bracket with all the parts attached to it can be rendved from the case without disconnecting any wiring by following the procedure described in the next paragraph. If a test jack is used, remove the two screws holding it to the front of the case. Remove the four screws holding the plug connector to the case and rotate the plug connector into a position from which it can be pushed through the rectangular hole to the inside of the case. After removing the four screws which hold the mounting bracket to the bottom of the case, the entire... assembly can be removed from the case. The plug connector has been assembled to the case in a fixture and doweled in place in order to insure alignment of the plugin sockets with the plugs on the equipment box plug connector. If it should become necessary to replace a plug connector with a new one, new holes (#52 drill size) for the dowels should be drilled in the plug connector and case in a new location. An equipment box rack can be used as a fixture for correctly locating the plug connector on the case. All wires except coil leads are No. 18 B.&S. gauge flexible stranded wire with extruded plastic insulation. The leads which are connected to the plug connector should be left sufficiently long to facilitate the operation of pushing the plug connector through the rectangular hole. 6097, p. 3
III. MECHANICAL INSPECTION Carefully examine all parts of the assembly to make certain that there are no improperly soldered joints, untightened screws or nuts or damaged insulation and that the lead wires are so arranged that they will not be pinched when the cover is applied to the case. IV. ELECTRrCAL INSPECTION The unit should be given a ground test by measuring the resistance between each terminal on the plug connector and the case with a 500-volt megger. This insulation resistance should be greater than 25 megohms. The unit to be tested should be plugged into place in the proper space on an equipment box-shelf. Also in place on this shelf should be an amplifier, a master relay, the other decoding units normally used with the equipment and a Style PN-59 decoding relay for each_ decoding unit1 except when a Decoding Transformer Unit is being tested, no PN-59 relay is used with it. A 32-volt d-c supply and a receiver circuit should be connected to the shelf as shown in Figure 3. The track current should be adjusted to a value approximately twice the pick-up value of the amplifier at 32 volts. Care must be taken to maintain d-c supply at exactly 32 volts. 6097, p. 4
A. Decoding Unit {75-Code), N451463-0501 Connect a standard phone plug to the terminals of a highly damped 0-100 ma d~c milliammeter such as a Westinghouse Type PX-4 or a WABCO PX-50 Code Meter, J620886, with the+ terminal of the meter connected to the tip of the plug and the meter's - terminal connected to the plug's sleeve. Insert the phone plug into the test jack on the decoding unit. The plug should freely enter the jack and snap into place on the jack with no tendency to jar out. The track current should be coded over contacts of a code transmitter from which code frequencies of 426 {see Note), 274 (see Note), 184.5, 123 and 72 are obtainable. The decoding relay current should be read on the tuned decoding units in accordance with Service Manual 6096 and should conform to the limits given in that instruction pamphlet. The decoding relay current should be read in the 75-code unit at all code frequencies and should conform to the values_ given in Tabler. Table I Code Frequencv Minimum Relay Current (ma.) 426 (see Note) 50 274 (see Note) 50 184.5 50 123 so 72 50 If the decoding relay current does not conform to the values given in the above table, the cause may be either a defective decoding transformer or reactor, or a defective bridge assembly. The decoding transformer and reactor may be tested in accordance with paragraph A of Section V - DETAIL PARTS SPECIFICATIONS. A defective rectifier part should be replaced by a new one. With the master relay operating on 426 (see Note) or 184.5 code, whichever is applicable for system in use, observe whether there is any sparking at the master relay contacts. If more than a very light spark is observed it is evidence that the 2 x 0.5 rnfd capacitor connected across the decoding transformer primary is defective. 6097, P 5
B. Decoding Transformer Unit (75-Code), N332749-D66026-Sh.5 The track current should be coded over contacts of. a code transmitter from which code frequencies of 426 (see Note), 274 (see Note), 184.5, 123 and 72 are obtainable. The decoding relay current should be read in the tuned decoding units in accordance with Service Manual 6096 and should conform to the limits given in that instruction pamphlet. If the decoding relay currents do not conform to those values and the tuned decoding units are known to be in good condition, the cause may be either a defective decoding transformer or 37.5-ohm resistor. These may be tested in accordance with paragraph A of Section v - DETAIL PARTS SPECIFICATIONS. NOTE j Code frequencies of 426 and 274 used only for cab signaling systems which employ 420 and 270 code rates. C. Decoding Unit (SO-Code), N435462-D66026-Sh. 13 Connect a standard phone plug to the terminals of a highly damped 0-100 ma d-c milliammeter such_ as a Westinghouse Type PX-4 or a WABCO PX-50 (J620886) with the+ terminal of the meter connected to the tip of the plug. Insert the phone plug into the test jack on the decoding unit. The plug should freely enter the jack and snap into place on the jack with no tendency to jar out. The track current should be coded over contacts of a code transmitter from which. code frequencies of 426 (see Note), 274 (see Note), 184.5, 123, 72 and 48 are obtainable. The decoding relay current should be read on the tuned decoding units in accordance with Service Manual 6096 and should conform to the limits given in that instruction pamphlet. The decoding relay current should be read in the 48-code unit at all code frequencies and should conform to the values given in Table II. If the decoding relay current does not conform to the values given in Table II, the cause may be either a defective decoding transformer or defective rectifier. The decoding transformer may be tested in accordance with paragraph B of Section V - DETAIL PARTS SPECIFICATIONS. A defective rectifier should be replaced by a new one. Observe master relay contact sparking as described under IV-A. 6097, p. 6
Table II Code Frequencv 426 (see Note) 50 274 (see Note) 50 184.5 50 123 50 72 50 48 50 Minimum Relay Current (ma.) D. Decoding Transformer Unit (SO-Code), N435483-D66026-Sh. 12 The track current should be coded over contacts of a code transmitter from which code frequencies of 426 (see Note), 274 (see Note), 184.5, 123, 72 and 48 are obtainable. The decoding relay current should be read in the tuned decoding units in accordance with Service Manual 6096 and should conform to the limits given in that instruction pamphlet. If the decoding relay currents do not conform to those values and the tuned decoding units are known to be in good condition, the cause may be either a defective decoding transformer or 37.5-ohm resistor. These may be tested in accordance with paragraph C of Section V - DETAIL PARTS SPECIFICATIONS. Observe master relay contact sparking as described under IV-A. NOTE Code frequencies of 426 and 274 used only for cab signaling systems which employ 420 and 270 code rates. V. DETAIL PARTS SPECIFICATIONS A. Decoding Unit (75-Code), N451463-0501 and Decoding Transformer Unit (75-Code), N332749 1. Decoding Transformer N326769 The resistance of the primary should be 147 ohms ±10% and that of the secondary 22.4 ohms ±10%. With 50 volts, 60 Hz applied to terminals lp and 3P, the primary current and the voltages should be as shown in Figure 4. The voltages should be read with a vacuum tube voltmeter. 6097, p. 7
8 8 8 MASTER PN S RC LA y s DOD OECOOING UNITS RELAY o--... --+32 o-----32 MAIN TERMINAL BOA RO l"t TC EQUIPMENT BOX SHELF coo TRANSMITTlll CONTACT VAlllABL AUTO TRANSFORMER TRACK TRANSflORM!ll 1.00HM STANOARO RECIIVl!R AT NORMAL LOCATION WITH RESf'ECT TO RAILS ~ Figure 3. Circuit for Testing and Tuning Decoding Units 0-711CM.1 A.C.MIUJAUIIIITIR U- tn... 50'... 21' tn. "' JP IS ~ + as Figure 4. Circuit for Testing Decoding Transformer N326769 6097, p. 8
The cores are clamped together by steel bands, and the coil are core assembly is held to the mounting bracket by the same type bands. The application of these bands requires special tools, therefore the master transformer {including mounting bracket) should be removed from the Decoding Unit, carefully packed and returned to US&S when repair is required. Contact the nearest US&S Sales Office for shipping instructions. 2. Reactor The resistance of the reactor coil should be 18.4 ohms,+ 10%. The impedance of the reactor should be measured byapplying 50 volts, 60 cycles to the coil terminals and measuring the current flow in the coil. This current should be between 61 and 64 ma. The two halves of the core are clamped together against non-ferrous metallic spacers. The coil and core assembly is held to the mounting plate by a phosphor-bronze band. The application of these bands requires special tools, therefore the reactor should be removed from the Decoding Unit, carefully packed and returned to US&S when repair is required. Contact the nearest US&S Sales Office for shipping instructions. 3. capacitor and Resistor The measured capacitance of each section of the capacitor should be 0.5 mfd ±10%. The measured value of the resistance of the resistor in the Decoding Transformer Unit should be 37.5 ohms ±5%. B. Decoding Unit {SO-Code), N43S462 1. Decoding Transformer N435501 Resistance of Primary - 360 ohms ±10% Resistance of Secondary - 30 ohms ±10% Apply 65 V to terminals 15 and 25, the current and voltages should be as shown in Figure 5. The voltages should be read with a vacuum tube voltmeter. 6097, p. 9
o-75 A.C.MA. A ZS 3P 30MA. 65V. tl0% 2P 60Hz. IS IP 576V±2,,o 578Vt2% Figure 5. Circuit For Testing Decoding Transformer N435501 Since special tools are required for the assembly of the decoding transformer, defective units should be returned to US&S for repair. Contact the nearest US&S sales Office for shipping instructions. 2. capacitor and Resistor The measured capacitance of each station of the capacitor should be 0.5 mfd ±10%. The measured value of the resistance of the resistor in the Decoding Transformer Unit should be 37.5 ohms ±5%. 3. Thyrector Diode J726110 Apply 75 V rms 60 Hz across terminals - should not exceed 12 milliamp~res. the current c. Decoding Transformer Unit N435483 1. Decoding Transformer N435484 Primary resistance - 370 ohms ±10% Apply 220 V, 60 Hz to terminals lp and 2P - the current and voltages should be as shown in Figure 6. Since special tools are required for the assembly of the decoding transformer, defective units should be returned to US&S for repair. Contact the nearest US&S Sales Office for shipping instructions. 0-15 A.C.MA. 220V. 60Hz. 3P --------A)----o------2-P-< Z20V. 60Hz ±5 MA. 10 % IP Figure 6. Circuit For Testing Decoding Transformer N435484 6097, p. 10
2. capacitor and Resistor The measured capacitance of each section of the capacitor should be 0.5 mfd ±10%. The measured value of the resistance of the resistor in the Decoding Transformer Unit should be 37.5 ohms ±5%. 3. Thyrector Diode J726110. Apply 75 V rms, 60 Hz across terminals - should not exceed 12 milliamperes. the current VI. ORDERING REFERENCES A. Decoding Unit (75-COde), N451463-0501, Dwg. 0451463-Sh. 5 Item Pc. No. Dwg. Sh. 1. case R326747 066025 10 2. Socket M331279 9954 259 3. Handle J056269 8311 188 4. 5. Decoding Transformer Capacitor (2 x 0.5 mfd) N326769 J070839 CI6918 1 6. Rectifier Assembly N451464-1601 B451464 16 7. "L" Reactor N326770 Cl6918 2 8. Test Jack N263133 12619 18 9. Jack Board N263135 8750 3320 10. Bushing N263134 8095 791 11. Cover M326761 066025 11 12. Inspection Record Plate J630521 8225 1249 B451496 24 13. Name Plate M451496-2401 14. Roll Pin J487041 15. Diode 1N4004 J723621 16. Thermistor 5 ohms J730918 9065 486 B. Decoding Transformer Unit, N332749, Dwg. 066026-Sh. 5 Item Pc. No. Dwg. Sh. 1. Case R326747 066025 10 2. Socket M331279 9954 259 3. Handle J056269 8311 188 4. Decoding Transformer N326769 Cl6918 1 5. Capacitor (2 x O. 5 mfd) J070839 6. Jack Board M332812 8750 3320 7. Cover M326761 066025 11 8. Inspection Record Plate J630521 8225 1249 9. Name Plate J063205 8225 464 10. Roll Pin J487041 11. Bracket M332813 10914 3311 12. Resistor (37.5 ohms) J720174 9065 358 6097, p. 11
c. Decoding Unit (SO-Code), N435462, Dwg. 066026-Sh. 13 Item Pc. No. Dwg. Sh. 1. 2. 3. 4. s. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Case Socket Handle Decoding Transformer Capacitor (2 x 0.5 mfd) Rectifier Thyrector Diode Test Jack Jack Board Bushing Cover Inspection Record Plate Name Plate Roll Pin Resistor (37.5 ohms) R326747 M331279 J056269 N435501 J070839 J723978 J726110 M263133 M263135 M263134 M326761 J630521 J063205 J487041 J720174 066025 9954 8311 C16918 12619 8750 8095 D 66025 8225 8225 9065 10 259 188 11 18 3320 791 11 1249 464 358 D. Decoding Transformer Unit, N435483, Dwg. 066026-Sh. 12 Item Pc. No. Dwg. Sh. 1. 2. 3. 4. s. 6. 7. 8. 9. 10. 11. 12. 13. 14. Case Socket Handle Decoding Transformer Capacitor (2 x 0.5 mfd) Jack Board Cover Inspection Record Plate Name Plate Roll Pin Bracket Resistor (37.5 ohms) Bushing Diode, Thyrector R326747 M331279 J056269 N435484 J070839 M332812 M326761 J630521 J063205 J487041 M435492 J720174 M263134 J072610 D 66025 9954 8311 C 16918 8750 D 6 6025 8225 8225 B 35027 9065 8095 10 259 188 11 3320 11 1249 464 609 358 791 6097, p. 12
TOPOt: JONES SOCKET (VIEWEO /:"ROM INSIDE OF CIJS ) ~:-. I I I IZ /(},-----1-I-:' n // 9 To,. or.5oc:91:c:ide of C.a.ac) (... fl"om~1n v,aw- ~. -~ ;JI Pl PS CD ---1. ~ l ljecolj/nt; TRAN$FO!i'Nl R RECllFIE > Dc:coo1,..a, TIIIAN$P'OfllMl:ll Topta up" 1.!>" leoq and tie to coil. 31.S~ ''t." li'eactq!i' TESTJ/ICK ' 0 ' -...J t'tj.... w Wiring Diagram for 7 5-Code Decoding Unit, N451463-0501
0 ' \0...,.. "O.....,:. TOP OF SOCKET (VIEWED FROM INSIDE OF CASE) ~ i-;-i I Pl P3 CD.I -...,. 1, -~ TOP OF JONES SOCKET (VIEWED FROM INSIDE OF CASE) ~;:====1-..:...------~~---. 0 10 I Pl P3 CD II 7 DECODING TRANSFORMER AC DECODING TRANSFORMER + IP 3P 2P AC 11.1-. 17,IJ.A THYRECTOR DIODE THYRECTOR DIODE TEST JACK Wiring Diagram for Decoding Transformer Unit, UN435483-D66026-Sh.12 Wiring Diagram for 50 Decoding Unit, UN435462-D66026-Sh. 13