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SERVICE MANUAL 6349
Description , Installation and Maintenanc~
TUNED MINIBOND
Part Numbers
June, 1985
ID0037F/DN0007F
UNION SWITCH & SIGNAL
A-3/88·25 2776-2
AMERICAN STANDARD INC./PITTSBURGH, PA. 15237
COPYRIGHT 1988,
PAINTED IN USA
usas DIVISION OF AMERICAN STANDARD INC.
U}
UNION SWITCH & SIGNAL
REVISION INDEX
Revised pages of this manual are listed below by page
number and date of revision.
•
UNION SWITCH & SIGNAL
CONTENTS
Section
•
~'
I.
GEN.~RAL INFORMATION
1
1.1
1.2
1. 3
1. 3 .1
1. 3. 2
INTRODUCTION
DESCRIPTION
SPECIFICATIONS
Electrical
Mechanica 1
1
II•
INSTALLATION
3
2.1
2.1.1
2.1. 2
2.1. 3
2.2
GENERAL
Track Preparations
Installation of Cables
Cable Connections
APPLICATION
III.
FUNCTIONAL DESCRIPTION
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
BASIC CONCEPTS
DESIGN CONCEPTS
General
Bond Impedance Across the Track Terminals
High "Q" Parallel Resonant Circuit
Series Connected High 'Q" Parallel Resonant Circuit
Minibond Impedance Versus Frequency Analysis
Conclusions and Comments
IV.
MAINTENANCE
25
4.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
FIELD INSPECTION AND MAINTENANCE
SHOP MAINTENANCE
Troubleshooting
Tuning
Impedance Adjustment
Bond Assembly
25
25
25
29
34
36
1
1
1
2
3
3
3
3
4
13
APPENDIX - A PARTS LIST
i
13
16
16
16
19
19
19
23
tlj
b'j
UNION SWITCH & SIGNAL
LIST OF ILLUSTRATIONS
Figure
2-1
2-2
2-3
2-4
Floating Concrete Slab and Direct Fixation
cone rete Ties
Wood Ties
Vagheux Concrete Ties
Application of 4 or 5 Hole 'T' Plate Connector
AF-Mini Impedance Bond - Basic Circuit
Typical Propulsion current Flow
AF-Mini Impedance Bond - Circuit Application
Minibond Schematic
Equivalent Circuit of Figure 3-4
Parallel Resonant Circuit
Impedance Versus Frequency
Reactive Impedance Versus Frequency
Impedance Versus Frequency - Three Circuits in Series
Circuit View From One Resonant Circuit
Impedance Reflected To Cable Terminals
Tuning Circuit Test Set-Up
Impedance Measuring Test Set-Up
AF-700 Tuned Minibonds Wiring Schematic
Capacitor PCB Tuning
Capacitor Tuning
2-5
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
4-1
4-2
4-3
4-4
4-5
5/6
7/8
9/10
11/12
12A/12B
13
14
15
17
18
20
21
21
22
22
24
27
27
31
32
33
I')
LIST OF TABLES
Table
Table
Table
Table
Table
Table
1
2
3
4
5
6
Component Values
Tuning Data
Nameplate (Operating) Data
Adjusting Capacitor Values
Capacitors/Part Numbers
Impedance Adjusting Resistor Selections
ii
28
30
30
35
35
37
UNION SWITCH & SIGNAL
t:ij
SECTION I
GENERAL INFORMATION
(
1,1
INTRODUCTION
The Tuned Minibond is an extension of the basic audio frequency (AF) minibond with
a center tapped primary and an inductively coupled secondary winding that is tuned
to increase the impedance of the bond at desired frequencies.
1,2
DESCRIPTION
Like the basic AF Minibonds, the Tuned Minibonds have a center- tapped propulsion
winding and permit coupling of ac signals between the secondary winding and the
propulsion winding. The Tuned Minibond differs in the number of cores and
secondary windings. The Tuned Minibond has three magnetic cores. Each core has
two secondary windings. The propulsion winding is common to all three cores (see
Figure 3-4).
The high turn secondary winding of each core is tuned to a particular frequency
(depends on the part number of the bond), The low turn secondary windings are
series connected. The group is connected to the high side of a coupling
transformer. The wayside equipment would be connected to the low side of the
transformer. The use of two secondaries per core allows the tuned windings to be
isolated from each other.
.,,.,;,
Since each parallel resonant circuit has its own magnetic core, the bond impedance
can be represented as the sum of the reflected impedances of the resonant
circuits. This is true for both the propulsion winding termination and the wayside
termination. The impedances can be complex. Section 3.2 (Design Concepts)
discusses the above in more detail.
Each circuit is tuned to a different frequency called the resonant frequency. At
the resonant frequency the impedance of the resonant circuit is high, The
reflected impedance to the track or wayside will also be high, In summary, the
bond's reflected impedance to the track or wayside terminals will be high near any
one of the three resonant frequencies. Away from the resonant frequencies, the
bond impedance will be low.
1,3
1,3.1
SPECIFICATIONS
Electrical
a.
All Tuned Minibonds
Style:
Type:
DC Resistance:
current Unbalance:
DC Propulsion current:
AF Mini
DC Propulsion
0.00003 + 10% ohms, rail to rail at 20°c
250 amps de through one turn of the
propulsion winding, based on the operating
characteristics of the AF-700 track circuit
system.
3000 amps de per rail (continuous)
6349, p. 1
ti::f
UNION SWITCH & SIGNAL
b.
Impedance and Resonant Frequencies
Part No.
Suffix
-1802
-1803
-1804
-1805
Track Trans.
Freq, +5%
Z+l0%
0.663
0,760
0, 875
0.868
2590
2970
3690
3870
Cab Trans.
Z_±l 0%
Freq. +5%
1.15
1,15
1.15
1.15
4550
4550
4550
4550
Track Rec.
Z+l0%
Freq. +5%
1. 73
1.58
1. 35
1. 55
3870
3690
2590
2970
Some bonds are off-tuned at given frequencies to increase their de
unbalance current capacity. Values are based upon zero amps of de
unbalance current, at 2ooc and at specified voltage levels,
Impedance values will vary with variations of these parameters.
1.3.2 Mechanical
The Tuned Minibond utilizes moly-permalloy toroidal cores to construct three
coils, Each coil has two windings, The three coils are bound together to form
a coil assembly, The low turn windings of the coils are series connected. Two
J-shaped bars of 1-1/4 inch copper are passed through the window of the coil
assembly to form the two-turn track winding, The coil and core assembly,
mounting plate, receptacle box connector, inserts, and screws are assembled into
a mold, The mold is then filled with an epoxy compound and cured.
The mold forms a cavity at the back of the bond. There are four long studs
inside the cavity. These studs are used to mount a circuit assembly, Each
circuit assembly contains two boards, One board contains a coupling transformer
and capacitors for tuning the bonds, The other board contains the resistors
used to adjust the impedance of the bonds.
A sealing compound is applied to the back edges of the bond where the cover is
assembled. The cover will make contact with a steel plate on the resistor
printed circuit board. This provides a heat sink path for resistors located on
the reverse side of the plate.
A two-pin connector protrudes from one side of the bond, This is where the
connection to the wayside equipment is made. A nameplate is located on the
opposite side,
Six 1/2-13 by 1-3/8 (approx,) inch studs protrude from the bottom of the bond,
These studs are welded to the mounting plate mentioned earlier. These studs are
used for mounting the bond during installation.
6349, p. 2
c;;
UNION SWITCH & SIGNAL
EE
SECTION II
INSTALLATION
(
2.1
GENERAL
WARNING
TO AVOID PERSONAL INJURY WHILE INSTALLING IMPEDANCE BONDS, BE
SURE TO DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE
WORKING AREA.
NOTE
Installation requirements for an impedance bond are controlled
primarily by the physical specifications of the user's
trackage and associated signal hardware. The following
remarks and drawings are intended only as a general guide to
installation. The customer should make whatever adjustments
are necessary to insure (a) that the bonds, cables and other
pieces are well secured, with no possibility of being damaged
by low hanging vehicle rigging, wheel flanges, etc. and (b)
the section of track outfitted with the bonds maintains
standards for tie spacing, ballast support, etc.
2.1.l
Track Preparations
Using the appropriate installation drawing for the impedance bond, reposition and
refashion the ties as needed to meet basic mounting requirements for the unit and
any auxiliary pieces such as a protective ramp. Replace any deteriorated ties
which may not hold attachment screw threads reliably. Where necessary, excavate
ballast between the ties to insure that the bond will rest flush against the ties.
Use the application drawing to locate hold-down screw holes for the bond and other
pieces, with the object of installing the equipment on the center line between the
rqils.
2.1.2
Installation of cables
Bond-to-bond cables are prepared according to the basic distance between bond units
and special requirements such as crossbonding to other tracks. Propulsion cables
should be prepared with length sufficient to take up rail running motion. Have the
ties support the cable as much as possible and secure the cable to the tie so that
only the outward end absorbs rail movements.
2.1.3
Cable Connections
A tin foil gasket (M06961) has been used between cable lugs and impedance bond
terminals. This gasket improves conductivity by filling imperfections in the
mating surfaces. The same result is achieved by tinning the terminals and lugs.
6349, p. 3
t:tj
UNION SWITCH & SIGNAL
a.
When a tinned or smooth surface lug is used with an impedance bond having
tinned terminals, the tin foil gasket may be omitted.
b.
A tin foil gasket shall be used between the mating surfaces of an
impedance bond terminal and cast cable lug or where the mating surfaces
are not smooth.
Corrosion at the bond terminal connections can be reduced by coating the connecting
surfaces with a corrosion preventive type of oil or grease. A conductive type is
recommended.
2.2
APPLICATION
Figures 2-1 through 2-4 provide information for the application of the tuned
minibond to 115 lb. RE rail at sites employing the following:
a.
floating concrete slab and direct fixation (typical), Figure 2-1.
b.
concrete ties, 30" or 33" spacing (typical), 30" shown, Figure 2-2.
c.
wood ties (typical mounting), Figure 2-3.
d.
Vagheux concrete ties (typical mounting), Figure 2-4.
6349, p. 4
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UNION SWITCH & SIGNAL
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SECTION III
FUNCTIONAL DESCRIPTION
(
3.1
BASIC CONCEPTS
The Tuned Minibond design and application is an extension of the basic concept
described below. The basic circuit configuration for an audio frequency (AF)
minibond is represented by a primary winding with a center tap and a secondary
winding inductively coupled to it (see Figure 3-1). The secondary winding may be
tuned to increase the impedance of the bond at desired frequencies.
The center-tap divides the primary winding into two sections having an equal number
of turns. Ideally the de resistance of each section would be the same. The
primary winding carries the propulsion current, hence it is constructed with heavy
copper.
----·-···--·-··- - - - - - - - - - - - - - - - · - · - - - - ~
CENTER TAP
Figure 3-1.
Typically, propulsion current
variations exist.
AF-Mini Impedance Bond - Basic Circuit
can flow through the bond in four ways.
Other
1.
~nters from both rails and exits at the center-tap, see Figure 3-2A.
2.
Enters from the center-tap and exits at both rails, see Figure 3-28.
3.
Enters at one rail and exits at the other rail.
would not be used, see Figure 3-2C.
4.
Enters at one rail and exits at the center-tap or vice-versa, see Figure
3-20.
usually, the center-tap
6349, p. 13
UNION SWITCH & SIGNAL
RAIL 1
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Figure 3-2D.
-·---·
Figure 3-2. Typical Propulsion Current Flow
6349, p. 14
UNION SWITCH & SIGNAL
(
tij
For cases 1 and 2, the total de propulsion current flow is divided between the two
halves of the primary winding. The current direction in one half will be opposite
the current direction of the other half. The magnetic fluxes induced in the
magnetic core of the bond will oppose each other and thus will tend to cancel each
other. Equal currents (balanced) will cancel completely. An excessively large
current unbalance will cause a loss in the ac signaling impedance.
The signaling current (ac) enters through one rail and exits through the other
rail. It traverses the whole winding in one direction, hence no ac flux
cancellation occurs. An ac signal is induced into the secondary winding.
similarly an ac signal can enter the secondary winding and induce a signal into the
primary coil.
For case 3 the bond allows the propulsion currents to be re-distributed. In
general, this tends to equalize the current in the rails. In this application, the
bond does not benefit from cancellation of the de current induced magnetic fluxes,
hence the de unbalance current capacity is reduced. The unbalance capacity becomes
half of the established rating since current flows through both halves of the
propulsion winding, In addition, the current capacity of the bond is also one-half
of the established unbalance capacity.
case 4 is similar to 3 except that the current flows through one turn instead of
two. The bond will handle the established unbalance current rating.
A typical application of an audio frequency style minibond system is shown in
Figure 3-3. The center tap on each bond is shown unconnected, however in certain
applications the tap may be used for connections to other bonds on the same or
adjacent tracks.
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6349, p. 15
D'::I
UNION SWITCH & SIGNAL
3.2
DESIGN CONCEPTS
3.2,1
General
Figure 3-4 shows a general schematic of minibonds N451003-1802 through -1805,
These bonds are tuned to three frequencies: cab transmitter, track transmitter and
track receiver. The track winding is common to all the toroids, The high turn
winding of each toroid is the inductor of a parallel resonant circuit, Each
parallel resonant circuit inductor has a core that is independent of the other
resonant ciccuits,
Figure 3-5 shows an equivalent circuit of Figure 3-4, The resonant circuits have
been reflected to the low winding side of the toroidal coils,
3,2,2
Bond Impedance Across the Track Terminals
The inductance of the track winding is around one micro-henry. The reactance
across the track terminals will be very low in the audio-frequency range, A value
of 0,03 ohms would be typical at 5000 Hz, The impedance can be increased by tuning
the winding. Tuning a secondary winding instead of the track winding allows use of
smaller capacitors. High impedances require high circuit "Q's" and will only occur
near the resonant frequency.
The minibonds have three parallel resonant circuits connected in series. The
impedance across the track terminals will be the vector sum of the reflected
impedances of each resonant circuit. The reflected impedances add (as in series
instead of parallel) because induced voltages are proportional to the change in
flux through its winding, The cores of all the resonant circuits pass through the
track winding, hence the track winding sees a total flux equal to the sum of the
individual core fluxes. current passing through the track winding will cause a
voltage drop across the terminals, The voltage will be transformed to the
secondaries. The power imparted to each secondary will be determined by the ratio
of the secondary reflected impedance to the total reflected impedance, The voltage
impressed across each secondary will depend on:
a. the secondary reflected impedance.
b, the turn ratio between that secondary and the track winding,
When the impedances of all the resonant circuits are low, the impedance across the
track terminals will be low. If the impedance of even one of the resonant circuits
is high, then the impedance across the track winding will be high, An exception to
this is when two or more high impedance resonant circuits develop a series
resonance between them, In this case, the vector sum of the reflected impedances
will be low.
6349 I p, 16
UNION SWITCH & SIGNAL
(
155:207
TRACK RECEIVER
CIRCUIT
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Figure 3-4,
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Minibond Schematic
6349, p. 17
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6349, p. 18
CABLE
TERMINALS
Equivalent Circuit of Figure 3-4
UNION SWITCH & SIGNAL
3. 2. 3
1:)1
High 'Q' Parallel Resonant Circuit
The following discussion assumes knowledge of parallel resonant circuit
characteristics. Figure 3-6 illustrates the general characteristics of a parallel
resonant circuit having a high circuit "Q". Figures 3-7 and 3-8 illustrate
relative impedance characteristics of three high 'Q" parallel resonant circuits
having (1) different resonant frequencies and (2) non-overlapping bandwidths.
Refer to Figure 3-7. Note that the impedance at the resonant peaks is much greater
than the impedances between the peaks. The impedance at a peak of one circuit is
much larger than the sum of the magnitudes of the other circuit impedances.
Refer to Figure 3-8. Note that between the resonant peaks some curves are positive
and some are negative. If these impedances were connected in series, they would
tend to offset each other.
3. 2. 4
Series Connected High "Q" Parallel Resonant Circuits
Figure 3-9 illustrates the magnitude of the impedance for the three parallel
resonant circuits of Figures 3-7 and 3-8 connected in series. Note that this curve
appears similar to Figure 3-7. It is possible that the impedance peaks will occur
at frequency values slightly different than those in Figure 3-7.
Between resonant peaks, the parallel resonant circuit contributes reactive
impedance of opposite sign. At particular frequencies, series resonance will
occur. Such resonance will occur once between peaks.
3.2.5
Minibond Impedance Versus Frequency Analysis
a.
View from Track Terminals
Refer to Figure 3-5. The coupling transformer is connected in parallel
to the series network of parallel resonant circuits. Signals from and
to the wayside cable are coupled through this transformer. If this
transformer impedance was sufficiently low, the impedance across the
track terminals would also be low. Figure 3-10 shows the circuit
viewed from one resonant circuit.
Note that if a series resonance occured in the right circuit branch, a
low impedance would also be produced across the track terminals. A
series resonance occurring near one of the parallel resonant
frequencies is not acceptable. The design of the coupling transformer
prevents such undesirable resonances from occurring.
The coupling transformer is designed to have a relatively large
impedance, and will have little effect on tuning of the resonant
circuit coils. Any shift that does occur is compensated for during
factory test.
6349, p. 19
EE
UNION SWITCH & SIGNAL
----- - --·- -----
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····---· ·····---
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IMPEDANCE VERSUS
FREQUENCY, TYPICAL HIGH "Q"
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. , - - - - - - REAL PART
+ Z OHMS
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X NEGATIVE IS CAPACITIVE
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2.
3.
4.
5.
6.
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Z has an inductive component when l<fr
'l has a capacitive component when I> Ir
Z has no reactance at f Ir
fr 1/(2n (LC) V,) for high "Q"
at resonance Z = w2L2/R = Owl = URC
When parallel resonance occurs, the loop current
sees series resonance.
1. w =
=
=
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Pigure )-6.
6349, p, 20
Parallel Resonant Circuit
UNION SWITCH & SIGNAL
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1-------------·---·--·--Figure 3-7.
Impedance Versus Frequency
l
REACTIVE Z
OHMS
CIRCUIT
#1
CIRCUIT
#2
CIRCUIT
#3
FREQUENCY (Hz)
Figure 3-8.
ReaCtive Imped.ance VersUS Frequ-e-nc_y___________,
6349, p. 21
UNION SWITCH & SIGNAL
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BANDWIDTH
Figure 3-9, Impedance Versus Frequency
._. ____ Three_.circuits in series
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Circuit View From One Resonant Circuit
UNION SWITCH & SIGNAL
b.
b'j
View from Wayside Terminals
Figure 3-11 shows the impedance bond reflected to the cable terminals.
The resonant circuits will short the coupling transformer except when
one or more circuits have a high impedance, or when the left branch
exhibits a parallel resonance with the transformer, Again, the design
of the coupling transformer prevents it from resonating in the
frequency range of interest for AF signaling.
c,
Compensation for Cable capacitance
Minibonds are tuned with a 0.1 MFD capacitor across the wayside cable
terminals. This is to account for the maximum capacitance expected
from the fl4 twisted pair cable, In the field, during initial track
circuit adjustment, a capacitor will be added in parallel with the
cable as required so that the total capacitance is 0,1 MFD.
3.2.6
Conclusions and Comments
a,
There will be one resonant frequency for each parallel resonant
circuit, No additional parallel resonance will occur in the desired
frequency range.
b.
Factory tuning procedures compensate for the effects of one circuit
upon another and for the 0,1 MFD capacitance expected in field
application.
c,
Factory testing procedures check each bond for proper tuning and
impedance.
c.
In theory, resonant frequencies at the cable terminals will be the same
as those at the track terminals.
6349, p. 23
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UNION SWITCH & SIGNAL
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Impedance Reflected To cable Terminals
6349, p. 24
I;
.
UNION SWITCH & SIGNAL
OJ
SECTION IV
MAINTENANCE
4.1
(
FIELD INSPECTION AND MAINTENANCE
WARNING
TO AVOID PERSONAL INJURY WHILE MAINTAINING OR
REPLACING IMPEDANCE BONDS, BE SURE TO DISCONNECT
PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA.
No disassembly or internal repairs shall be attempted on any impedance bond
if trouble is suspected, A defective bond unit must be returned to the
manufacturer as shipped. Field maintenance shall consist of periodic visual
inspection of the bond for a cracked bond and bent, loosened and corroded
terminals. Corroded terminals may be cleaned (with appropriate abrasive
materials) and cable lugs retightened, however, in the event of case or
terminal damage as specified above, the complete bond should be returned to
the manufacturer.
All cables should be inspected for possible impact damage or fraying due to
corrosion, and replaced if such problems are found, Also, tightness of
various tie hold-down screws should be checked to make sure the bond is held
securely to the ties.
4.2
er
SHOP MAINTENANCE
4.2.1
Troubleshooting
:":'.
S..:::;)
a.
Types of Failures
1.
b.
Loss of impedance
(a)
Component failure
1. Short
2, Open
( b)
Broken wire
(c)
Bad or poor connection(s)
2.
Impedance increase
3.
Intermittent
Determinin9 the Cause of Failure
Information is provided below to assist the user in troubleshooting and repair
of the bond if the user so desires. However, return of the bond to the
factory is recommended.
6349, p. 25
UNION SWITCH & SIGNAL
1. sweeping the Frequency to Find Peaks
The best method to analyze bond failures is to test the bond in the
circuits of Figure 4-1 or 4-2. A source voltage is applied and then the
frequency is swept through the audio frequency range. Voltage peaks across
the wayside terminals or the track terminals are noted. These peaks should
occur at or near the ~uning frequencies of the bonds. There should be
three peaks.
The absence of all peaks indicates one or more of the following:
(a)
(b)
(c)
(d)
(e)
(f)
shorted coupling transformer
broken wire in the bond
loss of connection
track winding shorted
open winding in the coupling transformer
incorrect wiring
DC continuity tests
continuity test can
center-tap joint is
transformer primary
can be used to check cases wb", "c", and "e". A
also determine if the track winding is shorted if the
insulated. For cases "b" and 'e' the coupling
winding must be disconnected from bond leads sl and s2.
case 'a' can be tested by bypassing the coupling transformer.
now appear, then the transformer was the problem,
If the peaks
The presence of one or more peaks indicates that the problem lies in the
resonant circuits. The absence of a peak during a frequency sweep
indicates which circuit(s) is (are) causing the problem.
2. Impedance Increase
Due to the nature of the design in the Tuned Minibonds, an increase in
impedance can occur in two ways.
(a)
The 'Q" spoiling resistor(s) of the resonant circuit in question has
decreased in value (i.e. shorted).
(b)
Component failure of one resonant circuit shifts the tuning of that
circuit to a resonant frequency near the resonant frequency of another
circuit. This type of failure would cause an impedance loss at the
original resonant frequency of the circuit shifted.
3. Resonant Circuit Impedance Loss
Some possible causes:
(a)
(b)
(c)
(d)
Increase in "Q" spoiling resistor(s)
poor connections
shorted capacitor(s)
open capacitor(s)
(e)
shorted coil
(f)
(g)
(h)
open coil
broken wire
incorrect wiring
6349, p. 26
UNION SWITCH & SIGNAL
1S
FREQ.
COUNTER
(AUOIO)
J
POWER
AMP
(AUDIO)
12000
160 W
1P
1:9
160
OUTPUT
1
..
[""°
TO
30000
190 W
(Max.)
Ill :
TO BOND
PIN CONN.
"A"
-~
-~
TO BOND
PIN CONN •
"B"
POLYPROP.
.111 FD
48
3P
IMPEDANCE MATCHING
TRANSFORMER
VARIABLE
SINE-WAVE
OSCILLATOR
1000-10000 Hz
DIGITAL
VOLT
METER
CAPACITOR
DECADE
BOX(ES)
SCOPE
PLACE
ACROSS TDD
CAPACITOR
POSITIONS
PER TABLE 2
'
CONNECT TO
Vtc leads
per table a
Figure 4-1 Tuning circuit Test Set-Up
POLYPROP.
VARIABLE
SINE-WAVE
OSCILLATOR
1000-10000
Hz
.111FD\
40
1P
1S
2:1
FREQ.
COUNTER
(AUDIO)
POWER
AMP
(AUDIO)
II I
4S
120 W
40
TO
m
[
3
l
Vz
100 W
(Max.)
4T
IMPEDANCE MATCHING
TRANSFORMER
Figure 4-2 Impedance Measuring Test set-Up
Note:
t)'j
Power amp output watts should exceed the combined wattage
required to operate the transformer and test circuits of the
bond, A high impedance transformer is recommended,
6349, p. 27
ti::J
UNION SWITCH & SIGNAL
Disconnect the resonant circuit coil leads and make a continuity test
across the coil leads. This checks for case "f'.
If the coil is not open, then connect one of the coil leads and make a de
continuity test across the remaining coil lead and its connection point.
The test should be applied until a stable reading is obtained, since
circuit capacitors will draw current until they are charged. If continuity
exists then capacitor(s) is (are) shorted (case "c").
For the remaining cases, measure the component values and compare them
against what they should be as listed in Table 1.
c.
Repair of the Determined Failure
1. Coil: The bond cannot be repaired unless the failure is due to a broken
accessible lead.
2. Capacitors can be replaced. Consult the parts list for capacitor
information. Replacement requires a tuning check and possibly an
adjustment. The larger the capacitor value, the more likely an adjustment
will be required.
3. Resistor(s): If a resistor fails, it is bast to replace the whole resistor
plate, since the resistors are difficult to access. Note the resistance
values originally used or else impedance adjustments may be necessary.
4. Poor connections should be cleaned and/or tightened.
5. Broken wires should be replaced.
Table 1.
Bond
suffix
1802
1803
1804
1805
Coil *
Resonant Circuit
Type
Leads
Frequenc~
Q
(X 10-6 Farads)
(Hertz)
35
11.1
11. 3
0.70840
0.21095
0.15425
2590
4550
3855
T4
T2
R2
5.33 +0.15
5.80 +0.15
11.05 +0.15
35
11.1
11.3
0.53877
0.21095
0.16936
2970
4550
3679
&
T4
T2
R2
5.33 +0.15
5.80 +0.15
11.05 +0.15
35
11.1
11.3
0. 35112
0.21095
0.34173
3679
4550
2590
&
&
T4
T2
&
R2
5.33 +0.15
5.80 +0.15
11. 05 +o. 15
35
11.1
l l. 3
0.31979
0.21095
0.25988
3855
4550
2970
&
TT
CAB
TR
T3
Tl
Rl
&
TT
CAB
TR
T3
Tl
Rl
&
TT
T3
Tl
Rl
&
&
&
&
&
-
-
0
• Measured at 1 volt, 1000 Hz, at 20 c.
6349, p. 28
Min.
Resonant
5.33 +0.15
5.80 +0.15
11.05 +0.15
T3
Tl
Rl
'PR
Inductance
(Millihenries)
Approx. Capacitance
T4
T2
R2
TT
CAB
TR
C/18
component Values
UNION SWITCH & SIGNAL
4.2.2
a.
t:i:j
Tuning
General Tuning Procedure
1.
2.
Each bond has three frequencies:
(a)
The track transmitter frequency (TT)
(b)
The cab transmitter frequency (CAB)
(c)
The track receiver frequency (TR)
Bonds are to be tuned to each of the frequencies called for in the
following order.
1st-track transmitter frequency (TT) (varies)
2nd-cab frequency= 4550 Hz (always)
3rd-track receiver frequency (TR) (varies)
The TT and TR frequencies are tabulated in Table 2.
3.
The track transmitter and the track receiver frequencies are generally not
tuned to the frequencies listed in the bond tabulation (operating
frequencies). Bond tuning will use the frequencies tabulated in Table 2
(tuning frequencies).
4.
Bonds are tuned by adding small values of capacitance. These capacitors
are located on printed circuit board N451657-92XX. They are added to the
circuit by soldering #18 buss wire to the appropriate turret lugs (see
Figure 4-3 wiring schematic) •
5.
Bonds are adjusted for impedance in a similar fashion. This adjustment is
made on printed circuit board N451657-91XX per Section 4.2.3 after the
bond is tuned.
6.
Both printed circuit boards are assembled into an assembly, N451662-11XX.
C·.
9
b.
Specific Tuning Procedure
1.
Read Section 4.2.2A (General Tuning Procedure) before tuning bonds.
2.
Assemble circuit of Figure 4-1.
3.
Adjust the frequency generator to the desired frequency,
4.
Connect temporary jumpers to the resistor terminals (see Figure 4-3): RlR
and R2, 0.25 ohms; TlR and T2, 1.5 ohms; T3R and T4, 2.0 ohms. However,
if permanent jumpers are already in place these may be tried first.
,.
Adjust the source voltage to obtain 1/2 the tabulated Vtc for vtc ('rabl,,
2) for the frequency concerned.
6349, p. 29
e3
Table 2.
"'w...
"'
Track Transmitter Tuning
'
'O
Minibond
N451003-
Freq.
+ 5
(Hz)
Vtc
+ 3
(Volts)
1802
1803
1804
1805
2590
2970
3679
3855
lSJ
153
153
153
w
Pc. No.
0
Track Receiver Tuning
Cab Transmitter Tuning
z
.±_10%
(Ohms)
Freq.
+ 5
(Hz)
VR
c
z
0
z
~
Tuning Data
z
~
z
Vtc
+ 1.5
(Volts)
.±_10%
(Ohms)
VR
(Volts)
Freq.
+ 5
(Hz)
Vtc
+ .5
(Volt~)
.±_10%
(Ohms)
VR
(Volts)
75.0
75.0
75.0
75.0
1.15
1.15
1.15
1.15
3.48
3.48
3.48
3.48
3855
3679
2590
2970
10.0
10.0
10.0
10.0
2.25
1.89
1.35
1.55
0 .1600
0.1905
0.2667
0.2323
.."'
5
o.663
0.760
0.890
0.883
18.10
15.79
13.48
13.59
4550
4550
4550
4550
Vtc
PCB Capacitor Positions
PCB Capacitor Positions
PCB Capacitor Positions
Measured
Across
Cl through ca
C9 & ClO, Cll & Cl2, Cl3 & Cl4
Cl5 & Cl6, Cl7 & Cl8, Cl9 & C20
C21 & C22
C23 through C30
Table 3.
Track Transmitter
1802
1803
1804
1805
vz
z
z
+ .05
(Volts)
.±_15%
(Ohms)
Freq.
+ 5
(HZ)
vz
+15%
(Ohms)
Freq.
+ 5
(HZ)
vz
+ 3
(Volts)
+ .005
(Volts)
+15%
(Ohms)
2590
2970
3690
3870
3.00
3.00
3.00
3.00
0.663
0.760
0.875
0.868
4550
4550
4550
4550
1.00
1.00
1.00
1.00
1.15
1.15
1.15
1.15
3870
3690
2590
2970
0.090
0.090
0.090
0.090
1.73
1.58
1.35
1.55
When Vtc = 153 volts
Vz = 3.00 volts
Vtc
Freq.
z
Track Receiver
Freq.
+ 5
( Hz)
NOTE
Note:
r
Nameplate (Operating) Data
cab Transmitter
z
z;,,
NOTE
NOTE
When Vtc = 75.0 volts
Vz = 1.00 volts
Voltage across resonant
Frequency (Hz= cyles/sec.)
Impedance magnitude
When Vtc = 10.0 volts
Vz = .090 volts
Values are based upon O amps
de unbalance current at 2ooc
•
n:in
UNION SWITCH & SIGNAL
S1
el
S2
..•• ~IT[fJt~
......
"'
'"
BOND LEADS
(FOUND IN CAVITY)
!1
-
0
'"
'"
"'
'-"'"'
~"'
\S>';;;
13
-
M
-
M
'-"~
"'
'-";:
c-,
_.,
0
~w
"'"'
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~ '-"
..,'""'
u
0
0
0
0
0
0
0
~.:
(§') ~
~
)
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0
0
o-,[1[1[101] ......
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A
~~
-- -
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u "'
B
0
0
"' u
'-"~
"'
"'"'
"'
><W
0
'-"';:
Al
..........
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OJd UOllJVdVJ
:%
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,.1:::
w
u-
~z
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~
ffi
uuuuu
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JU MPEAS PROVIDED ON
CIRCUIT ASS EMBLY
N451622·11XX
el
(,'
()
r,
',
(,'
1:)
I=
101
14
-
~
~
~
~~
12
~~
-
·- 9..
F,o~-~
~~"'
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~[;:; 1-,
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ti,:;;
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,:~
1ri
N
'-"'~
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'-"'~
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.,
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_,
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w~
aaz
0
0
;:
"'
,:!
0
~
-0
N
"' "'
i= 0--"0'" O•N-0
FINE !UNI:~
JUMPERS
,:~
---·-·
ACTUAL USE DETERMINED
DURING TUNING TESTS.
-
,.-~
,:;
l
~
I'!
~. ~.
-~
.
____ _____ ... ·-····--·-·.. -·-------------~
,
Figure 4-3.
AF-700 Tuned Minibonds Wiring Schematic
6349, p. 31
tij
UNION SWITCH & SIGNAL
,r- -,-- -,.--r- _
I
I
J_
' r .,. T - - r
1
n===~ I
I
l I I I I
I
TSII
l I I I
~®
r.l!!!~O~ J
0 0
I
I
,-r
- r - -·
1
g
I
I
b.
l
CAB
\J-le..
0
·
I~==='==.
I
ISS-C
~
0
CAPACITOR PCB
. ~~1657-92
CAB
r---
---1
I
1
I
I
I
I
,- - - -
----,I
I
I
IL __ _
I
I
I
I
I
I
I
I
- - - IIJl:l\Cl\iE"~ E\.lii'C.iR\&.fl\.\.Y.
c.u,-,..:,e_c.,-1,t:, 'TV~~er
\.u C..~
I
I
,...,
'4. ... ----- * lF C.Af'l\c.i-roRS l'.a'E" "ll.E"",
.:}""'PERS
TR.Ac.to
TR~t-.)S.t-i1 I TTI:?
R,
Pigure 4-4.
6349, p. 32
'""'<,,-
lt->S.-rllLt.~t::,
Bia
""hie-----
\{t<..
T~AC.I(.
C.E\VE~.
ae
Capacitor PCB Tuning (Current Revision Layout)
Also see Pigure 4-5
,-j
UNION SWITCH & SIGNAL
ii
)>
:z
-f.
~
C")
..,,n
(/l ::0
;;:: )>
(")
en
...,
....
-f :,::
l _--_i:i"
1-
--0---0- --0---0- - -0
::0
,..., -f
V-1.c.
Tj?..,<\c.i,:
'i?,EC:.E lVl:R
I
(") :::,
,..., )>
~
(")
<
:,,:
;TJ
::0
n
"'
0
(")
N
u,
n
N
"'
(")
N
....
...,
N
0,
OJ? OJ? OJ? 05? OJ?
CAPACITOR PCB
N451657-92
REY
_1_ - ---- _-1~_ l __ _.__ _ J_ __ J
Figure 4-5,
Capacitor Tuning (Earlier Revision Layout)
Also see Figure 4-4
--- Dashed line indicates electrically connected turret lugs.
* No jumper or both jumpers are to be used for each set,
Do
not use only one jumper in a set.
6349, p. 33
er,
UJ
UNION SWITCH & SIGNAL
6.
Using temporary jumpers, add or remove capacitance until a voltage peak is
found for Vtc in Figure 4-4 or 4-5 (the scope or digital voltmeter
reading). Capacitor decade boxes are recommended for this.
WARNING
Circuit voltage may be high. Use insulated
tools or turn the power down.
7.
Adjust the source voltage to obtain the tabulated Vtc for Vtc.
8.
Vary the jumpers, increase or decrease capacitor decade box value until~
voltage peak is found.
WARNING
Circuit voltage may be high. Use insulated
tools or turn the power down.
9.
Turn the power down. Jumper capacitors into the circuit which approximate
the value of the decade box. Tables 4 and 5 are provided as guides.
Exception: for the cab transmitter frequency, two capacitors in series
are required. The capacitor values will be twice the value of the decade
box. Two jumper connections may be required to place PCB adjusting
capacitors into the circuit. The effective capacitance equals one half of
the value of one capacitor. The number of jumpers required depends upon
which PCB revision the minibond is equipped with.
10. Repeat steps 6 through 8 until the voltage peak occurs at the tabulated
Vtc.
11. With Vtc set to the tabulated value, vary the frequency until a voltage
peak is obtained. This frequency shall be within the tabulated tolerance
of Table 2.
12. Solder the appropriate capacitors into the circuit using #18 buss wire to
make permanent jumper connections. Excess length is to be trimmed. After
cooling, clean flux residue from the solder connections.
4.2.3
a.
Impedance Adjustment
Adjusting Impedance
1.
Assemble the circuit of Figure 4-2.
2.
Measure and record the resistance of the 4 ohm (approx.) resistor (R of
Figure 4-2).
3.
Apply the track transmitter frequency to the circuit.
value tabulated in Table 2.
4.
Verify bond is correctly tuned.
6349, p. 34
Set Vtc to the
~
UNION SWITCH & SIGNAL
Table 4.
Capacitor
Circuit
Positions
Track
Transmitter
Tuning
C4
C5
C6
C7
CB
Cab
Transmitter
Tuning
(Effective
capacitance
equals 1/2
the capacitor
values).
Track
Receiver
•runing
Cl3
Cl4
Cl5
Cl6
Cl7
Cl8
Cl9
C20
C21
C22
C26
C27
C28
C29
C30
Adjusting Capacitor Values
Capacitor Values (MFD) for Board Pc. No.
-1802
-1803
-1804
-1805
• 0033
.0068
.0100
.0220
.0330
.0022
.0047
.0082
.0150
.0330
.0010
.0022
.0047
.0082
.0150
.0010
.0022
.0047
.0082
.0150
.0022
.0022
.0047
.0047
.0082
.0082
.0100
.0100
.0150
,0150
.0022
.0022
.0047
.0047
,0082
.0082
.0100
.0100
.0150
,0150
,0022
.0022
.0047
.0047
,0082
,0082
.0100
,0100
.0150
,0150
.0022
.0022
.0047
.0047
.0082
.0082
.0100
.0100
,0150
,0150
.0068
• 0033
,0015
.0010
,0005
.0068
• 0033
.0015
.0010
.0005
.0150
.0068
,0033
.0022
.0010
.0100
,0068
.0033
.0022
.0010
1/11/!'!":<.
'"
Table 5 Capacitors/Part Numbers
Capacitance
Commodity No,
.00025
.0005
.001
.0015
.0022
.0033
.0047
.0068
,0082
.0100
.0150
, 0220
• 0330
.0470
.0680
.0820
.1000
• 1500
.2200
, 1300
,47
.68
.82
J709118
J700712
J709145-0576
J709145-0577
J709145-0578
J709145-0579
J709145-0580
J709145-0581
J709145-0582
J709145-0583
J709145-0584
J709145-0585
J709145-0586
J709145-0587
J709145-0588
J709145-0589
J709145-0590
J709145-0591
J709145-0592
,1709145-0593
J709145-0597
,1709145-0598
J709145-0608
6349, P· 3 r,
EB
UNION SWITCH & SIGNAL
5.
Reference Figure 4-2. When desired impedance (Table 2 or 3) occurs,
VR=(VZ) R/Z. Different values of VR (hence z also) can be obtained by
changing the jumper connections of the resistor(s) on printed circuit
board N451657-9101, when VZ is held at the tabulated value.
6.
Apply tabulated frequency to the circuit of Figure 4-2.
7.
Apply tabulated VZ to bond terminals while holding VZ at the tabulated
value. Vary jumpers until desired VR is obtained, (see Figure 4-3 and
Table 6) per Table 2 or 3. Measure and record the values of R, VZ and
VR. Calculate the impedance of the bond. Impedance= (VZ) (R)/(VR).
8.
Replace temporary jumpers with 118 buss wire and solder the buss wire to
the turret lugs. Exception: Use insulated wire for connections to T3R
and T4.
9.
Repeat steps 3 through 8 for the remaining frequencies (Cab Transmitter
and Track Receiver).
NOTES
(a)
A resistor decade box may be used to determine the amount of
resistance required. The closest available resistor selection is
then chosen.
A 5 amp rating is recommended for the decade box.
(b)
4.2.4
a.
An increase in value of the adjusting resistor will decrease the
impedance of the bond.
Bond Assembly
Final Assembly
1.
Apply Red Glyptal (A040171) to a corner of each terminal strip screw.
2.
Assemble printed circuit board assembly into the bond,
(A040171) to the nuts.
3.
Clean edges of the bond cavity with a clean cloth.
cavity edges and assemble covers.
4.
Check impedances at the operating frequencies per Table 3 and Section
4.2.3, Step 7.
Apply Red Glyptal
•
Apply RTV to the bond
NOTE
The purpose of th<' Red Glyptal is to prevent loosening of
tl1e screws a,1,i nuts ,iue to vibration. Any non-corrosiv,~,
non-conducting material that will perform this function may
be used.
6349, p. 36
UNION SWITCH & SIGNAL
Table 6.
Impedance Adjusting Resistor Selections
Track Transmitter
Terminals T3R, T4
Ohms, Resistors
o.o
'
i
;
I!
Short
.25
.50
.25 &
.75 &
.75 &
.75 &
.25
• 50
.75
1.00
1.25
1.50
I
Cab Transmitter
Terminals TlK, T2
Ohms, Resistors
o.o
TR
• 50
.25, Short • 5
•5
•5
&
.25
t:)j
Track Receiver
Terminals RlR, R2
Ohms, Resistors
o.o
•5
1.0
1.5
2.0
2.5
3.0
Short CAB
•5
1.0
1. 0' & • 5
2.0
2.0 & • 5
2. 0, Short • 5' 1.0
1.0
1.5
2.0
2.5
3.0
3.5
3.5
2.0
4.0
&
•5
&
1.0
I'
4.5
i
5.0
I
6.0
Short TT
1.0
l.5L
2.0
1.0 & l.5L
l.5L & 1. 5R
2.0, short
1. 0' 1. SL
1.0 & l.5L &
l.5R
2.0 & 1.0 &
l.5L
2.0, Short
1. 0' 1. 5L,
l.5R
2.0 & 1.0 &
l.5L & l.5R
-.,,
6349, p. 37
SERVICE MANUAL 6349
Appendix A
PARTS LIST
TUNED MINIBOND
Part Numbers
I I
j N4s 1oos-l 1so2 1sos 1so4 l1sos
Juno, 1985
ID0037F/DN0007F
A-3/88-25 2776-2
I
UNION SWITCH & SIGNAL
AMERICAN STANDARD INC./PITTSBURGH, PA. 15237
COPYRIGHT 1988. US&S DIVISION OF AMERICAN STANDARD INC.
PRINTED IN USA
APPENDIX A
PARTS LIST
Al,l
TUNED MINIBOND (Complete),
Cab
Cab
Cab
Cab
N451003-1802
N451003-1803
N451003-1804
N451003-1805
Part No.
200
205
Minibond Sub-Assembly (Basic)
Circuit Assembly (Used on -1802)
circuit Assembly (Used on -1803)
Circuit Assembly ( Used on -1804)
circuit Assembly (Used on -1805)
Washer, 1/ 4", Stl. Plate
Washer, 1/ 4", Stl. Lock
Nut, 1/ 4-20
Name Plate
washer, #10' Stl. Lock
Screw, 10-32 x 5/16
Cover
screw, 1/4-20 x 1/2, Hex
R.T.V.
Red Glyptal
N451003-1801
N451662-1101
N451662-1102
N451662-ll03
N451662-1104
J047501
J047775
J048002
M451607-6601
J047733
J052562
M451004-7101
J050012
A041652
A040171
Minibond Sub-Assembly (Basic) N451003-1801 (See Figure A-1)
Item
Description
Part No.
5
10
15
20
45
50
55
60
65
70
75
85
90
95
100
105
Coi 1 and Core Assembly
N451662-0901
N451004-4701
R451004-7002
A041844
A041498
M451005-0104
J709146-0252
J525164
J7 30039
J525340
M438881
M451005-0105
M438746-006
J079714
J460119
J475196
J475197
J480304
J725920-0009
J047501
J047775
J048002
*
*
*
*
*
*
*
*
*
*
*
*
llO
ll5
I
TR-3870
TR-3690
TR-2590
TR-2970
Description
Al.1.1
I
TT-2590;
TT-2970;
TT-3690;
TT-3870;
See Figure A-1,
Item
210
215
220
225
230
235
240
245
I
-4550;
-4550;
-4550;
-4550;
UNION SWITCH & SIGNAL
120
125
130
l .J 5
"J" Bar
Mounting Plate
Epoxy
Duct Sealer
Insert
Receptacle connector
Screw, 6 X 1/2 Rd. Hd,
Terminal, Pre-Insul.
Screw, 1/4 x 20 x 3
Insulating Bushing
Insert
Lead
Wire Marker
Bolt, 3/4 x 10-3/4, Hex Hd., Silicon Bronze
Washer, 3/ 4", Pl. Flat, Silicon Bronze
Washer, 3/4", Spr, Lock, Silicon Bronze
Nut, 3/4-10, Hex, Silicon Bronze
Spac0r, l/2 x 1/4 x l/2
Washer, l/4", Stl, Plate
washer, 1/4", Stl. Lock
Nut, l/4-20
* Encapsulated material, impossible or very difficult to replace, shown
for reference.
6349, p, A-l/A-2
tij
UNION SWITCH & SIGNAL
Al"PLY Rl!O l(YP'TAL
ON
Tl-tE.
!ER:MlNAL
S,TJ:tl~
§ DR ...rT
1---+--'--·'
\..---~l.-1::~-I
r+--r1• ,,
1
I
'
-
1
11
I
I
I
I
1
I
I
I , 1
1
1
1
I 1 11
11
1
1
I
1
I :r
f'<'
11,~
I ~::'' - J..J.;:''_J~
7ReF-
•
zJ
ljG
REF.
Vlf\./ 'S>HO'w'1NG
or
LOCA1"10N
R'EC.EPTAC.LE
liEM .. SS
~ {:OVER TO BE
A.t..'$0
t!R£F l---·-------------1,~RE'F
SEALED
'wlTl-1
~.i.V. (A04\i.o5Z).,
-=,~,,._'- I?. 1-\ol.E.S Oi..) '!oono-...... o~ 'T\-\'ic.
1!,.oi,JO.
------------!
4S
TH(
(z) ~
SS
F01.1.ow•"1C., ,NFOftMA.'1'10~ 'i, ~uP~\.lEO ,..oii FtEF. ON\.V
't.Al'PI.IC.A,.ION ::,we.'!> FOR. SIMILAR MINll!,oNt:7
(t.i4S'IOO' ••}llk.) 04,14 80:. 'i,,"'T'~, IO, 11, 12., 8... J!,
]l'.MUI.Tl•TAP 'T" Tl!:R.MINAL LUC. C.llNN~C.TOf.t'll
::,we;.,
A.
DlA.1-!0lf'~-
C.'f51004 -SI-I. 73
e.
(RtF.)
owe..
I
<llt•WJ>.Y
M4,I004•'T.JOI
Z !i•w'AI' M4.5t004• 7JOZ.
APPt•C.ATION
0451
)D,:--1A,T1N(;, C.ONt,,JE:C.TOR.
a1e • ~1-1.1e
'::,TR. ... IG,MT
l
A,.J.$. &. 'ii. i='ART N.O . .J"70914'- •0292'
B. (;.ONNE:C:.TOR TOOL':> - CAt.lNON P'AR.T NO\..
\. C.R1MP1N6
M·tt5t'OIJ •01
2. CRtMPINC. .OCATl>R
TPj"7
-'· G,u1oe: PIN'S,
2t(.,• ,OJIJ·OOO
4. N'S,[R.TION
C..IT-IZ
5.1<:EMOVAI..
C.ET·t'Z·'Z
...
C..RIG,I-IT
ANC.LE,U.4!..&.S.
:::>AR,TNO
.J70914<..·0291.
,'2.00 MtN.
, ?.00 MA.X.
CLE.O..R.0..tJC:.E. WI-IE._,
CLAMPED TOGETl-lE~
"*"
es
D~51003-18 Rev. 1
Figure A-1.
Tuned Minibond Assembly
6349, p. A-3/A-4
UNION SWITCH & SIGNAL
·P
Al.1:~·
Circuit Assembly (See Figure A-2)
~\·
-~
N451662-1101
N451662-1102
N451662-ll03
N451662-ll04
Item
5
10
15
20
25
30
35
40
45
.
--
(Used
(Used
(Used
(Used
on
on
on
on
N451003-1802)
N451003-1803)
N451003-1804)
N451003-1805)
Description
Part No.
Capacitor PCB (Used on -1101)
Capacitor PCB ( Used on -1102)
Capacitor PCB (Used on -1103)
Capacitor PCB (Used on -1104)
Resistor PCB
spacer Bracket
Screw, 8-32 x 7/16 Fl. Hd.
washer, #8, Lock
Nut, 8-32, Hex, Stl.
Washer, #8 Pl. Flat, Stl.
Wire, Teflon, #18
Terminal, Pre-rnsul.
N451657-9202
N451657-9203
N451657-9204
N451657-9205
N451657-9101
M451662-0102
J521081
J047681
J048166
J047745
A045010-0001
J730039
.
'
-
6349, p. A-5/A-6
UNION SWITCH & SIGNAL
NOTE ORIENTATION OF CAPACITOR PCB B
RESISTOR PCB PRIOR TO ASSEI.ELY
CRII.P TERMINALS IIT,401 ON EACH ENO OF A I FT,
PIECE OF WIRE (IT,451 ANO INSTALL BY MATCHING
TERMINALS TIR, TJR, 8 RIR,
YIHEN ROUTING WIRES FROM TERMINAL STRIP ON RESISTOR
PCB TO TERMINAL STRIP ON CAPACITOR PCB, INSERT
WIRES INTO RESTRAINT SLOTS ON THE EDGE OF EACH
&
PCB AS SHOWN
.----------,
,25
2,0
2,0
,5
.,
1,0
1,0
I, 5
!$©
________ .@
,15
R20
OT
0 ~!
r-------w,
lu2'-,_ffi
I
t~1
®--------L
1,-~~~~~~~~~~5%~~~~~~~~~~~--al
!REF >
COI.PONENT SIDE OF RESISTOR PCB
10
~~
- "'
5
~~~~J--i:
i~
35 30 25 20
F451662-ll Rev. 1
Figure A-2,
circuit Assembly
6349, p. A-7/A-8
UNION SWITCH & SIGNAL
Al. l. 2, l
Capacitor PCB (See Figure A-3)
+
+
+
+
Item
*
*
*
,,
•
5
10
15
20
25
30
35
40
45
50
55
Tl
N451657-9202
N451657-9203
N451657-9204
N451657-9205
(Used
(Used
(Used
(Used
on
on
on
on
-1101)
-1102)
-1103)
-1104)
Description
Part No.
Epoxy Sheet, 1/8"
Laminations
Coil
Screw, 4-40 x 1-1/2, Rd, Hd.
Washer, #4
Nut, 4-40, Hex
End Plate
Turret Lug
TSl, Terminal Block ( 6 Way)
TS2, Terminal Block ( 4 Way)
Wire, #18, Bare Tinned Copper
A77 2106
J792656
N451637-1101
J525093
J047765
J480006
M451611-1101
J714090
J752715-0013
J752715-0012
A04 31 79
For part number of capacitors Cl through C30,
see tabulation on Figure A-3,
+
Excluding capacitors, all items are part of the basic board
N451657-9201
*
Replacement and repair wi 11 usually require disassembly, This
can be time-consuming. Replacement of the complete board should
be considered.
6349, p, A-9/A-10
--------------------------~-
--
-
0)
UNION SWITCH & SIGNAL
SUFrlX USING
BASIC BOARD
-9201
OP[RATIIIG
FR[OUENCIES I H2 I
(FOR REFERENCE OtllYI
TT-TR
CAB
TRACK TRANSMITTER
CAPACITOR Cl
-
"· uo.
CAPAC I TOR C2
... ,.
-9202
2590
1870
<1550
J70'1145-05<)J
·"
-9203
2970
3690
<1550
J109145-0592
-9204
3690
2590
4S50
J709145-059J
·"
·"
-9205
J870
2970
4550
JT09145-0591
OPERA T ! NG
FREQUENCIES lttZl
(FOR RffERENC[ ONLY I
5UFFI~ USIUG
BASIC BOARD
-9201
."
PC.
CAPAC I TOR CJ
... ,. "· "'·
"'· ... ,. "· "'· .n
.,,
----
J709l 45-0568
,068
-----
TT l
CAB TRANSMITTER <CAB>
CAPAC J TOA CS
"· "'·
CAPACITOR C6
...,.
"·
uo.-----,.-;:
150,
CAPACITOR C7
"· "'·
CAPACITOR CB
"· "'·
I.FD.
. ,.
tm.
... ,. "· "'· ...,. "· "'·
"· "'·
CAl'AC!TOR Cl7
...,.
,068
J709 I 45-0586
• 068
J709145-0578
.oon
J709145-0578
,0022
J109145-0580
, 0047
,015
J709 I 45-0566
,03l
JTO'll45-0593
.n
J709145-059J
.n
J709145-oser
.068
J70'1!45-0588
,068
J709145-0578
,0022
J70'l145-0578
.0022
J709145-0580
.0047
,015
J709145-0593
."
J109145-0593
.n
J709145-0581
,068
J709145-056B
, 068
J709145-0578
.0022
J109145-0H8
,0022
J109145-0580
,0047
.ors
J709 I 45-0593
."
J70'll 45·05'13
.n
J70<) I 45-05%
.068
J709145-0588
, 068
JT09145-0578
,oon
J7091 45-05 78
.0022
Jl09145-0580
.Q047
·"
.0022
J109 I 45-0580
.0047
J109145-0582
,0082
---
J109!45-05H,
,001
J7091 4S-05 78
.0022
J709145-0~80 .0047
J709145-0562
,0082
JTO'll 45-0584
J709145-0516
.001
J709145-0578
,0022
J7091 45-0;00 .0047
J709 I 45-0562
,0082
J70'll 4S-0584
J109J 45-0584
.015
J709145-0584
.0!5
J709145-0590
J709!45-058l
.0,
J709145-0!64
.015
J709145-0584
,015
J709145-0591
• 0,
J709145·05B3
.o,
J70'1145-0~84
.QIS
J709 I 45-0564
,015
J709 I 45-0592
.o,
J709 I 4S-0583
.o,
J709145-0~64
,015
JT09 I 45-056~
,01 5
J709 I 45-0592
.0002
Jl09 I 45-0582
,0062
JT0'1!45-0583
·"
J709! 45-0582
,0002
J70'1145-0582
,0082
J70'1145-05Bl
J109 I 45-0582
,0082
J709145-0502
, 0002
J709145-0583
. 0047
J109145-0582
,0002
-920)
2970
3690
4550
J709!45-0500
,OOH
J709 I 45-0562
-9204
3690
2590
4550
J709145-0500
,0047
-9205
3870
2970
4S50
J709145-0580
,0041
"'·
PC. UO
• 0,
J709!45-0500
CONNECTOR TS I
CAPAC I TOR
• 0,
J709!45-058l
4!'>50
CAPAC I TOR CU
J709145-0SOJ
, 0082
3670
PC, NO.
CAPAC,lOll C21
...,.
J709!45-0582
2590
PC. tlO.
TRACK RECEIVER ( TR>
CAPAC I TOR
"'
... ,.
PC, NO,
-9202
PC, NO,
...,.
,rn.
J709 I 45-058Q
JT09 I 45-0518
...,.
TR CAB
"· "'·
''°'·
.n
J109145-0592
CllPACllOR Cl9
"· "'·
''°'·
CAPACITOR CIS
J709 I 45-0593
Jl09145-050J
CAPACITOR CIB
"· "'·
CAPAClTOll Cl4
.n
,0068
CAB TRANSMITTER
CAPACITOR C16
..,.
CAPACITOR CIJ
J709145-059J
JT0'114S-OS81
."
"·
CAPACITOR Cl2
CAPACITOF: Crl
,OB
,OOB
J709! 45-0584
...,.
CAPACITOR CtO
Jl09 I 45-0586
JT09145-0579
J709 I 45-0585
CAPAC I TOR C9
.on
JT09145-0593
J109145-0591
TT
<
. ,.
CAPAC I TOR C4
(
PC, NO •
PC, NO •
...,.
PC. UO •
...,
"'
,.
."
·"
·"
CAPACITOR CN
... ,.
PC. NO.
..,.
CAPACJ TOR C25
-------
---
PC. NO,
PC, RO,
. ,.
CAPACITOR C21
CAPAC J T<JR C26
"''·
PC, NO.
CAPACITOR C28
CAPACITOR C29
..,.
PC. RO •
CAPACITOR CJO
...,.
PC, RO.
PC, UO •
..,.
J709 I 45·0626
04067 J709145-058'
.0068 J709 I 45-0519
. 0033
J709145-0577
,0015
J709145-0576
,001
J100712
,0005
J709145-0561
,0068
J709145-0561
,0066
J709 I 45-05 79
, 0033
J709145-0577
,0015
J709145-0576
,001
J700TI 2
.0005
Jl09 I 45-0590
.,
J709 I 45-058·1
,015
J709 I 45-0561
, 0060
J709! 45-0579
.003l
J709145-0578
,0022
JT09145-0576
,001
J709!45-0585
,022
J709145-058l
.o,
J709 I 45-058 I
,0068
J709 I ~5-0579
.oon
J709 I 45·05 J8
, 0022
J709145-0576
.001
CONNECTOR TS2
ISS-B
)
1~ 11
~u u
~
~I~
I~
~
CIO
C9
0
0
0
! ss-c
N
c
N
N
00
01
CAPAC I TOR PCB
N451657-91
REV
lo
Q;::;
~I
0.
~
0
Cl2
Cl I
n
~
0
;::;o
0
0
s2Q
s1Q
~llld'ERS 8Elll£Ui !URJll:T lUGS ARE SHO~ fOR RH£R(l<CE O~lY,
ACII/Al USE Of JU•P(QS OCCURS l>I I~( TO!' HS•Y AS
DElERMJN[O IN TEST !PEC (11·6619
0
I
Pl
I
n
P2
I
I
n
_I~
0
·~
n
~
N
_I
~
1
L~]
I
L__ _J
0
0
0
F451657-92, 92A, 92E
Figure A-3.
Capacitor PCB
6349, p. A-ll/A-12
(
UNION SWITCH & SIGNAL
f:E
t
J
0
••"
"
(
•
'0 ~
'
;• •'
0
j
~
~
~
"
~
~
0
a a
•"· ".,;•
£
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.
0
0
£
..
0
,"•
0
0
1
2
~
r
0
;;
i i
0
0
•'
• l,"
3
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j
b
~
0
0
"j ~s
"'J")"'~
y
~o•
rr
~0 ~
•' s.
~
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,,
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~;
I
I
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~
~
u
~
0
~
~
~
•,
N~
3
Ng
§
~
..~·
t~
~
~
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!I'u
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r
0
,
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0
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~
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N
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rl
0
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8"
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l•'igure 2-5
Application of 4 or 5 Hole "T 11 Plate Connector
6349, p. 12A/12B
UNION SWITCH & SIGNAL
Al,1,2,2
Resistor PCB - N451657-9101 (See Figure A-4)
Item
Description
Part No.
10
15
25
30
35
40
45
50
55
60
65
Terminal Strip
Terminal Lug
Rubber Pad
Resistor Plate Assembly
Spacer
Screw, 8-32 x 1, Rd, Hd.
washer, #8, Flat
Washer, #8, Lock
Nut, #8' Hex
Rubber Adhesive
Wire, #18, Teflon, Black
J725715
J714090
M451662-0401
N451662-0301
J725920-0008
J052604
J04 77 45
J047681
J048166
J041531
A045010-0001
IJJc·.
~
6349, p. A-13/A-14
~
.,t
;g
UNION SWITCH & SIGNAL
•
ffi
•
'
.••I
(
'
•
,\------'I
•
•
IG 11':i· I.S'l t',\. J
NJ38JS}ll!S lN]NOd'<OJ
0
';P
rro
-
0
0
"]
0
0
,,,
~
~~
...
,,---<
'"
---<
0
0
96
"
0
~
::'
,,
>
~
~
---<
N
:,
<l)
~
r1
"'
r-I
"'"'
"'"
"'
r1
r
,.;
=
-~o
~-
"'x
~~
~
~~~ 0
=~
0
0
0
0oc
0
N
"~ "
®
m
Figure A-4.
~
~
-
N
::::::~
~z
Lie
-
0oc
~ ~
0
N
oc
r=o1-0;o:J.o
0
0
·--]
J
Resistor PCB
6349, p. A-15/A-16