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IUNION SWITCH & SIGNALI~ SM6468 1000 TECHNOLOGY DRIVE, PITTSBURGH, PA 15219-3120 Field Maintenance PD-1 STYLE VITAL PLUG-IN RELA VS COPYRIGHT 1992 UNION SWITCH & SIGNAL INC. PRINTED IN USA JUNE 1992 IUNION SWITCH & SIGNAL I~ SM6468 1000 TECHNOLOGY DRIVE, PITTSBURGH, PA 15219-3120 Field Maintenance PD-1 STYLE VITAL PLUG-IN RELAYS COPYRIGHT 1992 UNION SWITCH & SIGNAL INC. PRINTED IN USA JUNE 1992 UNION SWITCH & SIGNAL REVISION INDEX Revised pages of this manual are listed below by page number and date of revision. The change bar in the page margin of the revised page indicates the area of change. Paae No, Date of Revision A UNION SWITCH & SIGNAL CONTENTS SECTION PAGE NO. I GENERAL INFORMATION 1.1 1.2 1. 3 1.4 1. 5 1. 6 1. 7 1. 8 1. 9 1.10 1.10 .1 1.10. 2 1.11 1.12 1.13 1.14 1.14 .1 1.14. 2 1.15 INTRODUCTION ....................................... 1-1 GENERAL DESCRIPTION ................................. 1-2 PD-1 RELAY PRODUCT FEATURES .......................... 1-2 PD-1 RELAY MOUNTING OPTIONS .......................... 1-3 MAGNETIC CIRCUIT ..................................... 1-3 CONTACTS ............................................. 1-3 COVER ............................................... 1- 3 FRONT TEST POINT ..................................... 1-3 RELAY VOLTAGE ........................................ 1- 3 PLUG COUPLER ......................................... 1-3 Rear Service Plug Coupler ............................ 1-4 Front Service Plug Coupler ........................... 1-5 INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6 TERMINATION ......................................... 1-7 TERMINATION NOMENCLATURE ............................. 1-7 PLUG COUPLER MOUNTING ARRANGEMENT .................... 1-8 Rack Mounting ........................................ 1-8 Shelf Mounting ....................................... 1-9 TOOLS AND ACCESSORIES ................................ 1-9 II 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.7 2.8 2.9 III 3.1 3.2 3.3 3.3.1 3.3.2 3.4 3.5 3.6 3.6.1 FUNCTIONAL DESCRIPTION INTRODUCTION ......................................... 2-1 DC VITAL REL.,AY GENERAL OPERATION ..................... 2-1 DC BIASED VITAL RELAYS ............................... 2-1 LIGHT OUT RELAYS ..................................... 2 -5 MAGNETIC STICK RELAYS ............................... 2-6 MAGNETIC HEAVY-DUTY AND HEAVY DUTY CONTACTS .......................................... 2-7 Magnetic Blowout Relay ............................... 2-7 Heavy-Duty Contact Relay ............................. 2-8 SLOW PICKUP AND SLOW RELEASE (DROPAWAY) RELAYS ............................................ 2-8 SWITCH OVERLAY RELAYS .............................. 2-9 FLASHER RELAYS ..................................... 2 -10 INSPECTION AND TEST INTRODUCTION ........................................ 3-1 RECOMMENDED TEST EQUIPMENT ........................... 3-1 FIELD INSPECTION .................................... 3-1 Static Inspection .................................... 3-1 Dynamic Inspection ................................... 3-1 TEST PERFORMANCE ..................................... 3 - 2 DC RELAY TEST STAND ................................. 3 -2 TESTS ............................................... 3-8 Biased Relay Performance Tests ....................... 3-8 A-1 SM6468 UNION SWITCH & SIGNAL CONTENTS (Cont'd) SECTION PAGE NO. 3.6.1.1 3.6.1.2 3.6.1.3 3. 6. 2 3.6.2.1 3.6.2.2 3.6.2.3 3.6.3 3.6.3.1 3.6.3.2 3.6.3.3 3.6.4 3.6.4.1 3.6.4.2 3.6.4.3 3.6.5 3. 6. 5 .1 3.6.5.2 3.6.6 3.6.6.1 3.6.6.2 3.6.7 3.6.7.1 3.6.7.2 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Biased Relay Test Stand Procedure . . . . . . . . . . . . . . . . . . . . 3-9 Slow Release (Drop-Away) Relay Test . . . . . . . . . . . . . . . . . 3-11 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Slow Release Test With Test Stand . . . . . . . . . . . . . . . . . . . 3-11 Slow Release Test Without Test Stand . . . . . . . . . . . . . . . . 3-13 Slow Pick-Up Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Slow Pick-Up Test With Test Stand . . . . . . . . . . . . . . . . . . . 3-14 Slow Pick-Up Test Without Test Stand . . . . . . . . . . . . . . . . 3-14 Magnetic Stick Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Magnetic Stick Relay Test With Test Stand ........... 3-15 Magnetic Stick Relay Test Without Test Stand ......... 3-16 Switch Overload Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 OS Relay Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Flasher Relay Performance Test . . . . . . . . . . . . . . . . . . . . . . 3-18 Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Flasher Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Lightout Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Recommended Test Equipment . . . . . . . . . . . . . . ·............ 3-20 Lightout Relay Test Procedure . . . . . . . . . . . . . . . . . . . . . . . 3-10 APPENDIX APPLICATION INFORMATION SHEETS A.1 A. 2 A. 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 TYPES OF PD-1 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 LIST OF TABLES TABLE NO 3-1 A-1 PAGE NO. DC Relay Test Stand, Controls and Indicators .......... 3-5 Ordinary Acting, Biased Neutral, Low Voltage PD-1 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A-2 SM6468 UNION SWITCH & SIGNAL LIST OF ILLUSTRATIONS FIG(JR.E NO. PAGE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 PD-1 Vital Relay, With Mounting Bracket . . . . . . . . . . . . . . 1-1 PD-1 Plug Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 PD-1 Front Service Plug Couplers . . . . . . . . . . . . . . . . . . . . . 1-5 Rear Service Plug Coupler Indexing . . . . . . . . . . . . . . . . . . . 1-6 Plug Connectors and Plug Coupler Tabs . . . . . . . . . . . . . . . . 1-7 Rear Service Plug Coupler Nomenclature . . . . . . . . . . . . . . . 1-7 Rear Service Plug Couplers, Typical Mounting . . . . . . . . . . 1-8 Front Service Plug Couplers, Typical Mounting ......... 1-8 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-9 2-10 Simplified Vital Relay Arrangement . . . . . . . . . . . . . . . . . . . 2-2 PD-1 Relay Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Biased Relay, No Voltage Applied . . . . . . . . . . . . . . . . . . . . . 2-3 Biased Relay, Voltage of Normal Polarity Applied ...... 2-4 Biased Relay, Voltage of Reversed Polarity Applied .... 2-4 AC Operated Relay Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Magnetic Stick Relay, Normal Polarity Voltage Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Magnetic Stick Relay, Reversed Polarity Voltage Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .· . . . . . . . . . . . . 2-7 Typical Slow Release Snubbing Circuit . . . . . . . . . . . . . . . . 2-9 Flasher Relay Driver Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 3-1 3-lA 3-2 3-3 3-4 3-5 3-6 3-7 3-8 Biased Relay Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Plug Coupler Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 DC Relay Test Stand Controls and Indicators . . . . . . . . . . . 3-5 Basic Contact Indicators Configuration . . . . . . . . . . . . . . . 3-7 Operating Time Measurement, Test Setup . . . . . . . . . . . . . . 3-12 Time Interval Meter, US&S 911A, Front Panel . . . . . . . . . . 3-12 Switch Overload Relay, Test Setup . . . . . . . . . . . . . . . . . . . 3-18 Flasher Relay, Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Light Out Relay, Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 2-8 A-3 SM6468 .: UNION SWITCH & SIGNAL SECTION I GENERAL INFORMATION 1.1 INTRODUCTION This service manual contains field maintenance data for PD-1 Vital Relays (Figure 1-1). The purpose of the manual is to provide signal maintenance personnel with the data needed to understand PD-1 relay operation and how to perform field maintenance inspection and testing of the relays. Vital relay scheduled maintenance consists of periodic inspections and tests. The inspections and tests verify the relays are performing within the minimum In-Service Application Limits as specified on the Application Information Sheets for the relays. These sheets are contained in the Appendix at the rear of this manual. Relays not meeting the In-Service Application Limits must be replaced. Relays removed from service must be shopped for further testing and repair. Figure 1-1. PD-1 Vital Relay, With Mounting Bracket 1-1 SM6468 UNION SWITCH & SIGNAL 1.2 GENERAL DESCRIPTION The PD-1 vital relays described in this manual are de vital relays of the following types: a. Biased Neutral, including the following 1. Ordinary Acting with Low Voltage contacts 2. Ordinary Acting with High Voltage contacts 3. Slow Release and Slow Pickup 4. Ordinary Acting with Magnetic Blowout contacts 5. Light Out b. Magnetic Stick c. Switch Overload Stick d. Flasher All PD-1 Vital Relay types are plug-in relays designed for railroad and transit signal applications and manufactured to meet AAR requirements for vital signal relays 1.3 PD-1 RELAY PRODUCT FEATURES Each PD-1 Vital Relay possesses the following product features: a. Mounting with either rear or front-service plug couplers. b. Wire connectors with commercially available plug connectors (Faston) for easy wiring. c. Wide selection of coil resistance and contact configurations d. Contact protection by a transparent dust cover for visual inspection. e. Contacts that can be easily replaced when necessary. f. Relay that locks securely in its working position. g. Coded index pins to assure correct relay-type insertion. h. Test point accessible from the front of the relay. i. Plug coupler that accepts two plug connectors per contact point. 1-2 SM6468 UNION SWITCH & SIGNAL 1.4 PD-1 RELAY MOUNTING OPTIONS PD-1 relays satisfy the special needs of vital circuits in railroad and transit signal systems. PD-1 plug couplers are available for both front and rear service. This enables the PD-1 relays to be mounted in relay racks where rear service is possible, or on a wall or shelf where front service is necessary. For shelf mounting, a support bracket is combined with a front service plug coupler. All wires are terminated on the plug coupler by removable solderless plug connectors. The plug connectors are available with or without a locking feature. · 1.5 MAGNETIC CIRCUIT Magnetic circuits are constructed of non-aging material. The magnetic air gap is not disturbed when the coil or contacts are removed 1.6 CONTACTS Contact fingers and springs are manufactured of spring-tempered phosphore bronze. Individual contacts are removable and easily replaced. Movement of the armature operates the heel spring and assures proper contact wiping. Plug connectors are tin-plated. Contact material for low voltage front contacts is silver carbon. Heel and back contacts are made from fine silver. Heavy duty contacts are silver-to-silver. 1.7 COVER A cover of transparent molded non-yellowing material houses the relay contacts and armature structure. The cover is sealed to its frame by pressure against a gasket, providing a tight dust-proof moisture-protected assembly. 1.8 FRONT TEST POINT This testing facility is in series with the coil control circuit to permit deenergization of the relay while in service without disturbing the relay or wiring. The test point permits measuring of the relay coil current by insertion of a PD-1 current test probe. 1.9 RELAY VOLTAGE PD-1 relays are manufactured for different input or control voltages. For specific voltage values refer to the relay's Application Information Sheet contained in the Appendix at the rear of this manual. Higher voltages can be used, but the maximum dissipating power of the coil should not exceed lOW. 1.10 PLUG COUPLER Plug couplers must be ordered separately. As stated, two types of plug couplers are available: rear service and front service (Figure 1-2). 1-3 SM6468 UNION SWITCH & SIGNAL 1.10 .1 Rear Service Plug Coupler Rear service plug couplers are permanently mounted onto a relay rack. The wires are attached to the plug coupler with plug connectors from the rear. FRONT SERVICE PLUG COUPLER REAR SERVICE PLUG COUPLER Figure 1-2. PD-1 Plug Couplers 1-4 SM6468 UNION SWITCH & SIGNAL 1.10. 2 Front Service Plug Coupler The PD-1 Relay with a front service plug coupler (Figure 1-3) is supported by two rods. These rods are secured to the shelf or wall. When in its working position, the relay is secured by two nuts. For service, the two nuts are removed and the relay is pulled forward on the support rods until the plug coupler contacts are accessible. The design offers maximum space utilization, since relays can be mounted on a wall or on both sides of a relay rack I SHELF MOUNTING SUPPORT ROD PD-1 RELAY I The lower diagram shows the PD-1 relay in the test position :·:·:·:·:·:·:·:·:·;·:·:·:·:·:·:·:·:·:·:·:·:·:·:·:·:·:·:•:·:·:•:·:·:·:·:•:·:·:·:·:·:•:•:·:·:·:·:·:·:···:·:•:··-:·:·Y.-'•:·:•:•:·:•:·:•:·:·:,:,.;.;,;.;,;,;,;.;.;.:,.;.;,:,:·:·:·: Figure 1-3. PD-1 Front Service Plug Couplers 1-5 SM6468 UNION SWITCH & SIGNAL 1.11 INDEXING PD-1 vital relays and plug couplers are supplied with indexing (Figure 1-4). A code plate, unique to the relay, is furnished with the relay independent of type-of plug coupler for rear service (B, Figure 1-2) . REAR SERVICE PLUG COUPLER ADAPTER PD-1 RELAY MOUNTING BRACKET \ REAR SERVICE PLUG COUPLER ADAPTER CODEPLATE \ Figure 1-4. Rear Service Plug Coupler Indexing 1-6 SM6468 UNION SWITCH & SIGNAL 1.12 TERMINATION Plug coupler wire contacts can be terminated by solder connection or by plug (Faston) connectors with or without a locking feature (Figure 1-5). The solderless connectors with insulated sleeves are normally used. POSITIVE LOCK CONNECTOR STANDARD PLUG CONNECTOR TABS AT THE PLUG CONNECTOR Figure 1-5.Plug Connectors and Plug Coupler Tabs 1.13. TERMINATION NOMENCLATURE Rear service plug couplers are marked with nomenclature as shown in Figure 1-6. Plug couplers are equipped with 20 (2x10) double blade contacts (Tabs at the Plug Coupler, Figure 1-5) for easy termination. 0 COIL CONNECTORS +1--1 5FI--I H--1 581--1 3FI--I 181--1 Figure 1-6. Rear Service Plug Coupler Nomenclature 1-7 SM6468 UNION SWITCH & SIGNAL 1.14 PLUG COUPLER MOUNTING ARRANGEMENTS 1.14 .1 Rack Mounting PD-1 relays are secured in their plug couplers and can be easily removed. Plug couplers are mounted onto relay racks in signal cases central instrument houses, and relay rooms. Typical mounting arrangements are shown in Figures 1-7 and 1-8. ,____....___ 1-%· (44.45 mm) Figure 1-7. Rear Service Plug Couplers, Typical Mounting L_ Figure 1-8. 0 Front Service Plug Coupler, Typical Mounting 1-8 SM6468 UNION SWITCH & SIGNAL 1.14. 2 Shelf Mounting For wall and shelf mounting of PD-1 relays, a shock mounting base is available. For such mounting arrangements, a front service plug coupler must be used, or the wires can be connected directly to the relay terminals with plug connectors. 1.15 TOOLS AND ACCESSORIES A broad range of tools and accessories are available, including test plugs, plug connectors, crimping tools,etc. Also available is a relay test stand. The relay test stand facilitates testing of individual de relays out of the relay racks. The relay test stand is sufficiently portable for use in the field or in the shop. 1-9 SM6468 UNION SWITCH & SIGNAL This page intentionally left blank· 1-10 SM6468 UNION SWITCH & SIGNAL SECTION II FUNCTIONAL DESCRIPTION 2.1 INTRODUCTION This section contains functional descriptions of each type of PD-1 vital relay. Description of general operation of the relays is presented first. This is followed by brief descriptions of specific relay types. 2.2 DC VITAL RELAY GENERAL OPERATION Figure 2-1 illustrates the structure of a typical de vital relay. The arrangement shown in Figure 2-1 is a simplified drawing of a vital relay. Figure 2-2 illustrates the PD-1 style of vital relay. The major difference between the two illustrations is the location of the relay's coil and armature. The PD-1 style of vital relay has its coil mounted vertically in the rear of the relay structure and its armature installed on the bottom of the relay structure, as shown in Figure 2-2. The electrical and magnetic operation of most .styles of vital relays is the same. 2.3 DC BIASED VITAL RELAYS A biased relay is equipped with a permanent magnet and arranged so that the relay armature picks up only when de current is flowing in the coil in a prescribed direction. The AAR defines a biased relay as: "A relay that will operate to its energized position by current of one polarity only, and will return to its deenergized position when current is removed". The schematic symbol for the biased relay is: SINGLE COIL OR DOUBLE COIL OR +Al --+ 1-A .--------------------. +T* I - -- +A I I. I I I I I I I I I -A 1- --1 --+ OR +B --+ -e -B~ OR -~+A * "T" IS A FRONT TESTING CONTACT WHICH IS INTERNALLY WIRED IN SERIES WITH +A 2-1 SM6468 UNION SWITCH & SIGNAL CORE HINGE SPRING POLE PIECE ARMATURE PIVOT SPRING 'fJl:::~~==:::;;;;;;:;b=:::::::::1__ _:c:3~~:_- STOP PIN ARMATURE CONTACT DRIVER BRACKET HINGE BLOCK / .9'____ "'----.. . . FRONT CONTACT INSULATED CONTACT DRIVER HEEL CONTACT _.., BACK CONTACT ~ CONTACT BLOCK Figure 2-1. Simplified Vital Relay Arrangement REAR SERVICE BRACKET BACK STRAP CONTACT BLOCK FRONT CORE SLUG TOP COVER MOLDED COIL TAPER PIN CONTACT DRIVER PIVOT SHAFT ARMATURE / BOITOM COVER MAGNET ARMATURE BACK STOP CONTACT DRIVER ARM FACTORY DATA TAG Figure 2-2. PD-1 Relay Arrangement 2-2 SM6468 UNION SWITCH & SIGNAL NOTE The illustrations in Figures 2-3 through 2-5 are functionally applicable to all styles of vital relays. Remember, however, the physical arrangements can be different. With no current passing through the coil, the permanent magnet is positioned so that its magnetic flux passes through the armature, permanent magnet, pole pieces, and core, as shown in Figure 2-3. This condition holds the armature in the deenergized or dropped position. The high reluctance (magnetic resistance) of the air gap prevents magnetic flux from flowing between the armature and the pole piece extension. Assume that current is applied to the coil circuit, and current flow through the coil is in the direction in which its magnetism opposes the magnetism of the permanent magnet, as shown in Figure 2-4. This condition is comparable to a high reluctance in the path of the permanent magnet flux. The resulting magnetic flux path is through the core, pole piece, pole piece extension, and the armature. As a result, the relay is energized with the armature in the energized or picked position. HINGE SPRING COIL CORE POLE PIECE PIVOT POINT ARMATURE PIVOT SPRING POLE PIECE EXTENSION f~~§:~~~~~~~~~~-=-=_;c:i~~4- STOP PIN ARMATURE CONTACT DRIVER BRACKET HINGE BLOCK PERMANENT MAGNET MAGNETIC FLUX -------- INSULATED CONTACT DRIVER Figure 2-3. Biased Relay, No Voltage Applied 2-3 SM6468 UNION SWITCH & SIGNAL The armature remains up as long as the coil is energized. When the coil circuit is opened, the magnetic force opposing the permanent magnet is destroyed. Once more, the flux of the permanent magnet resumes the low reluctance path through the pole piece and armature. Since there is no force to hold the armature up, it drops away from the pole pieces. Assume voltage of the opposite (reverse) polarity is applied to the coil (Figure 2-5). This creates a magnetic force, which aids the magnetic force of the permanent magnet, and the flux remains through the permanent magnet, armature, and pole pieces. Thus, with voltage of the opposite polarity, the armature is not picked up. I I I MAGNETIC FLUX -------- •. __ ,----' N s Figure 2-4. Biased Relay, Voltage of Normal Polarity Applied MAGNETIC FLUX (COMBINATION OF BOTH COIL AND • • • • ..... • PERMANENT MAGNET FLUXES) I I I I I I I I I I I I I • .. __ Figure 2-5. Biased Relay, Voltage of Reverse Polarity Applied 2-4 SM6468 UNION SWITCH & SIGNAL 2.4 LIGHT OUT RELA VS The PD-1 Light Out Relay is designed for signal light-out detection applications. The relay is energized when the signal lamp being monitored is lit. It is deenergized when the lamp is burnt out. The relay is a biased neutral relay with two coils, that are electrically separate but magnetically coupled. The schematic symbol for the light out relay is: LO -cffi~J+ LOR OR N12---i One of the coils (0.15 or 0.37 ohms) is wired between relay terminals LlO and RlO. Connected between these terminals and in parallel with the relay coil is a diode rectifier. fn a signal lighting circuit, the signal's ac voltage is applied through this light out relay coil and rectifier circuit to the signal lamp. When a signal lamp's filament is not open, ac current flows through the 0.15 and 0.37 ohm coil and rectifier circuit. Polarity of the rectifier with respect to the coil must be correct for the relay to operate when the ac voltage is applied. As shown in Figure 2-6, energy is applied to the relay coil during the positive excursions of the ac power source. Being a biased relay, when the coil polarity is correct, the relay energizes. RECTIFIER AC SOURCE Figure 2-6. RELAY COIL AC Operated Relay Coil 2-5 SM6468 UNION SWITCH & SIGNAL After the relay energizes, a path is completed through a set of front contacts of the Light Out Relay. Through these front contacts, de voltage of the correct polarity is applied to the second coil (350 or 0.086 ohms) through terminals L8 and L9 of the relay. After the relay is energized by ac lamp current flowing through the first coil, energizing of the second coil holds the relay energized. 2.5 MAGNETIC STICK RELAYS The magnetic stick relay is similar in construction and operation to the biased relay. However, the armature is pivoted at its center and uses two permanent magnets; one at each end of the armature. The schematic symbol for the magnetic stick relay is: The design is such that the armature remains in the last operated position with full contact pressure after energy is removed from the relay coil. The relay moves to the alternate position when de voltage of opposite polarity is applied. I I I I I I I • ARMATURE • MAGNETIC FLUX ----11111--CENTER PIVOT NORMAL CONTACT CONTACT DRIVER HEEL CONTACT - ....----------~· REVERSE CONTACT CONTACT BLOCK Figure 2-7. Magnetic Stick Relay, Normal Polarity Voltage Applied 2-6 SM6468 UNION SWITCH & SIGNAL With polarity of the permanent magnets as shown in 2-7, and current flowing in the coil as indicated, the armature rotates counterclockwise. This action pulls up the contact driver, which, in turn, closes the heel and normal contacts. When the polarity of the voltage across the coil is reversed, the resultant magnetic flux, as shown in Figure 2-8, forces the armature to rotate clockwise. This pushes the contact driver down, which, in turn, opens the normal contacts and closes the heel and reverse contacts. I I I I I I I I I I • , __ _ • ARMATURE \ MAGNETIC FLUX -------- CENTER PIVOT CONTACT DRIVER Figure 2-8. Magnetic Stick Relay, Reverse Polarity Voltage Applied 2.6. MAGNETIC HEAVY-DUTY AND HEAVY-DUTY CONTACTS 2.6.1 Magnetic Blowout Relay The biased magnetic blowout relay is similar in structure and operation to the de biased relay. The exception is the use of magnetic blowout heavy duty contacts. Small permanent magnets are affixed to the contact springs, behind and close to the heavy duty tips. The purpose and effect of these magnets is to disperse or blow out an electric arc before it has the chance to grow and burn and otherwise damage the contacts. The coil symbol for the biased magnetic blowout relay is the same as that of the standard biased relay described in paragraph 2.3. The schematic symbol for the magnetic blowout heavy-duty contact is: • OR 2-7 • • SM6468 UNION SWITCH & SIGNAL This type relay is used in conjunction with other relays to control electric switch machines. 2.6.2 Heavy-Duty Contact Relay The heavy-duty contact relay is a biased relay with heavy-duty contacts. The relay is similar in structure and operation to the de biased relay with the exception of having heavy-duty contacts which can carry loads up to 15 amperes. Standard contacts are designed to carry loads up to 4 amperes. The coil symbol for the heavy-duty contact relay is the same as the biased relay, but its contact symbol is: CJ * 2.7 • CJ OR SLOW PICKUP AND SLOW RELEASE (DROPAWAY) RELAYS The slow pickup and slow release relays are biased relays, having special timing characteristics. Slow pickup and slow release refers to the relative timing of relay action. The desired pickup and release timing characteristics are achieved through the use of RC circuits. The schematic symbols for these relays is: SLOW DROPAWAY SLOW PICKUP +A +A -A -A OR OR Timing characteristics are changed externally by combinations of coil connections, and snubbing of coil circuits by combinations of rectifiers, capacitors, and resistors (Figure 2-9). As stated on the PD-1 Application Information Sheets for slow pickup and slow release relays, the snubbing components may be external or built into a plug coupler. 2-8 SM6468 UNION SWITCH & SIGNAL + SERIES COIL CONNECTION WITH SHUNT RECTIFIER. +A -A PICKUP NORMAL DROPAWAY SLOW -B + SERIES COIL CONNECTION WITH RESISTOR AND CAPACITOR SNUB. +A -A - -B PICKUP NORMAL DROPAWAY SLOWER THAN ABOVE. Figure 2-9. Typical Slow Release Snubbing Circuit. 2.8 SWITCH OVERLOAD RELA VS Switch overload relays are used to provide protection from overload currents for de switch machine motors. The operation time for these type relays is inversely proportional to the magnitude and duration of the overload current. The schematic symbol for the overload relay is: -------------------, I -A I +a I I I I +A - + 0 -B s 1H 2H I I I 28 ----------------J 2-9 SM6468 UNION SWITCH & SIGNAL The switch overload relay is placed in the switch machine motor circuit. The relay is constructed with two coils; an operating winding and a stick winding. The operating winding is wired in series with the switch machine motor. When current is excessive, the operating winding energizes the relay. The relay is held energized by the stick winding, causing deenergization of switch control relays that directly control the motor circuit. The activation time, hence the sensitivity of the overload relay, is determined by a low resistance element connected across the operating winding. The resistance element has a positive temperature coefficient so that a substantial increase in current causes a proportional increase in resistance. During normal current conditions, most of the current passes through the resistance element with little or no current through the operating coil. An increase over the normal current level increases the resistance of the element, causing more current to flow through the operating coil. If the overload persists, the operating coil receives sufficient current to activate the relay armature. 2.9 FLASHER RELAY The PD-1 flasher relay is a biased neutral relay with heavy duty front and back contacts. When the relay is used with an external electronic driver unit (Figure 2-10), it will provide between 41 and 45 flashes per minute when the voltage applied is 8-18V de. The driver unit is assembled in a package that plugs into a standard octal socket. The driver unit contains shop-adjustable controls to set the on-time and off-time of the flasher. The schematic symbol for a flasher relay is: OR 2-10 F -A SM6468 UNION SWITCH & SIGNAL NAME TAG RELAY DRIVER FRO PART NO. 75335001 CC DUST COVER FREQ. 43 :t2 PPM INPUT 10 -14 voe LOAD 250 • ADC PIN 1 -DC INPUT PIN 4 OUTPUT PIN 6 +DC INPUT TRANSCONTROL NEW YORK CC HEADER 8 CONTACT TEFLON TUBING ...L-~L_LLJ..:.L..=.t::;---- COMPONENT BOARD ASSEMBLY FLAT TAG, DIGIT 4 OR 6 14 X 71111" SCREWS Figure 2-10. Flasher Relay Driver Unit 2-11 SM6468 UNION SWITCH & SIGNAL This page intentionally left blank 2-12 SM6468 UNION SWITCH & SIGNAL SECTION Ill INSPECTION AND TEST 3.1 INTRODUCTION This section contains procedures to be used to periodically inspect and test PD-1 Vital Relays at their field locations. How often each type of vital relay is to be inspected and tested is specified in its Application Information Sheet contained in the Appendix at the rear of this manual. 3.2 RECOMMENDED TEST EQUIPMENT DC Relay Test Stand Source of 120V, 60Hz power 0-72Vdc Power Supplies (2) 0-40Vdc Power Supplies (2) DC Voltmeter DC Anuneter AC Voltmeter AC Anuneter 912B Low Resistance Ohmmeter 911A Time Interval Meter 912A Code Rate Monitor Simpson TS-111 On-Time Meter Test Leads, minimum of 2 sets, color coded (Red and Black) 3.3 FIELD INSPECTION 3.3.1 Static Inspection The following static inspection can be performed with the relay mounted in its operating position, or removed from its plug coupler. Check each inactive relay for the following a. b. c. d. e. f. Abnormally pitted and/or burned contacts Contact misalignment. Corrosion or other contamination of relay parts. Loose parts inside cover. Broken seal. Cracked or broken cover. 3.3.2 Dynamic Inspection With the relay installed in its operating position or in the Relay Test Stand, check the following while operating the relay: 3-1 SM6468 UNION SWITCH & SIGNAL Armature moves freely and that moving heel contacts meet the front and back contacts squarely and practically simultaneously. 3.4 TEST PERFORMANCE The PD-1 relay tests can be performed without the DC Relay Test Stand. But the test stand simplifies the test setup and reduces the time needed to test the relays. The following paragraphs describe how to test each type of relay with and without the test stand. Whether or not the test stand is used, the basic test setup is as shown in Figure 3-1. NOTE As a general rule when testing de relays, such as the PD-1 relays, an ammeter is used to test relays with a coil resistance under 100 ohms, and a voltmeter is used to test relays with a coil resistance over 100 ohms. 3.5 DC RELAY TEST STAND The DC Relay Test Stand is manufactured by US&S. Its formal title is Relay Test Stand PN-150/PN-250 Relays. To enable its use to test PD-1 relays, a Plug Coupler Adapter is provided with the test stand. The Plug Coupler Adapter is wired to a PN-250 frame which is inserted into the PN-250 mounting base on the test stand. The Plug Coupler Adapter sits on a test bench or other flat surface and the PD-1 relay to be tested is then inserted into the Plug Coupler Adapter. The DC Relay Test Stand is described in detail in US&S Service Manual 6360. The manual describes the test stand and contains detailed procedures for the testing of PN type de relays. To reduce frequent reference to the manual, the following information is included in this manual. Refer to Table 3-1 and Figure 3-2 for the location and function of each test stand control and indicator. It must be remembered that all of the test stand controls and indicators are not used for the testing of PD-1 relays. Located in the center of the test stand (Figure 3-2, item 19) are 30 contact indicators. The contact indicators are arranged in five rows of six indicators per row. During the tests, the indicators provide a visual indication of the relay's contact configuration and whether they are open or closed. During PD-1 relay testing, as shown in Figure 3-3, the contact indicators in columns 1 through 3 only are used. Row A and D indicate Front contact closure, Row B and E indicate Back contact closure. The Heels (H) can be imagined 3-2 SM6468 UNION SWITCH & SIGNAL as located between rows A and B, and also between rows D and E. In this basic six Front and six Back contact configuration, row 3.6 TESTS3. 6.1 Biased Relay Performance Tests M1 (Current Monitor) .--~---1A ,__~~~~~~~---. + S1 (SPDTP ..., .... POWER SUPPLY M2 (Voltage Monitor) Figure 3-1. ;cc "'..,cc > .., 0 z ·A +A cc RELAY UNDER TEST Biased Relay Test Setup RELAY TEST STAND~ PN·250 MOUNTING BASE PN-250 FRAME PLUG COUPLER ADAPTER \ -- ,,,tfY•• . ~00"- cry <iY <iY <iY :® ® -:::::. Figure 3-lA. Plug Coupler Adapter 3-3 SM6468 UNION SWITCH & SIGNAL Table 3-1. DC Relay Test Stand, Controls and Indicators REF ITEM FUNCTION 1 Relay Mounting Base PN-250 Provides the proper position and connections for testing the PN250 and PF-256 style relays. * 2 PN-250 Switch (S2) In the WITH TEST JACK position, the input to the relay coil is applied to the TEST contact. In WITHOUT position, input to coil is directly to the coil receptacle. 3 VARIAC Control (Vl) Varies the ac power input for testing the light out and power transfer relays.The variable input is the left ac jacks (15 and 16) 4 AC POWER Switch (Sl) In ON position, 115Vac line is connected to VARIAC (3) and transfonner that powers the lights. In OFF, power is cut. 5 Power Indicator (Ll) Lights when ac power is available to light the Contact Indicators (L2) (19). 6 PN-250 LIGHT SELECTION SWITCHES (Sl2) In 1 position, with rotary switch Sll (7), connects PN-250 base for testing other than PN250B relays. In 2 position, base is connected to test PN-25-0B relays. In OFF position, two front bottom row contacts are disconnected. 7 PN-250 LIGHT SELECTION SWITCHES (Sll) In 1 position, with toggle switch Sl2 (6), connects PN-250 base for testing 6FB-6F-3B PN250B relay. In 2 position, base is connected for testing 8FB-4F2B PN-250B and PF-256 flasher relays. 8 Relay Coil Block Jacks A+/A- Provides connections to single coil relays or, with item 10 (Jacks B+/B-) connects two coil relays in series or parallel. 9 Coil Polarity Switch (SlO) When using a power supply with Jacks A+/A- (8) and B+/B- (10), the NORMAL position applies positive (+) voltage to A+ (B+) tenninals and negative (-) voltage to A- (B-) terminals of biased, timer, light out, or power transfer relays. In REVERSE position, voltage to the A (Bl terminals are reversed. In OFF position, voltage is removed from both coil terminals. * Used to connect the PD-1 relay under test to the test stand via the Plug Coupler Adapter 3-4 SM6468 UNION SWITCH & SIGNAL 21 22 1 20 S3 <jj) S2 PARAWI. OFF <[}> COILS SINGLE 18 17 16 15 Pll-15GP S4 S5 S6 S7 <jj) <tr <tr Pll-15Clll AC VOLTIIIETBI 2 PN·ZSCII .H V1 IQQQQSS! • · !f.SSQQQj 3 VARW: IQSQQSSI --+----.,----,. --1-----.---.. lf.SSSSSI WITH mT JACI OFF REMOVE JUMPER TO READ CURRENT S13 L1 AC POO'R <[y 00 <jj) S1 4 TIMER 23 10 Figure 3-2. 10 DC Relay Test Stand, Controls and Indicators 3-5 SM6468 UNION SWITCH & SIGNAL Table 3-1. DC Relay Test Stand, Controls and Indicators (Cont'd) FUNCTION ITEM REF 10 Relay Coil Block Jacks B+/B- Provides connection to the second coil of two coil relays or, with item 8, connects two coil relays in series or parallel. 11 Fuse (Fl) Protects the VARIAC (3) and lights (Ll and L2) transformer. 12 PN-150 Contact Configuration Switch (S9) In position 2, the PN-150 base is connected for testing relays with 6 Front/Back contacts. In position l, the base is connected to test relays with 4 Front/Back, 2 Front, and 1 Back contacts. 13 Only PN-150T Switch (S8) In the ONLY PN-lSOT position (up), the proper PN-150 base contacts are connected to the +DC/-DC jacks (14). The 2 position is used for all other PN-150 type relays. 14 DC+/- Jacks Used with ONLY PN-150T switch (13) to supply input power to PN-lSOT relay. 15 AMPS or JUMPER When using AC current for Power Transfer or Lightout relay tests the AC armneter connects between these jacks. When voltage only is used, the jacks are jumpered. Jacks 16 AC VOLTMETER Jacks Used for connecting an AC voltmeter across relay coil in conjunction with four switches (17). 17 PN-lSOL (Light out)/ PN-lSOP (Power Transfer) Switches (S4,5,6,7) In PN-150BL position (down), the PN-150BL/PN-150P base is connected to test the PN-150BL relay. In the PN-150P position, base is connected to test the PN-lSOP relay. OFF position must be used to test all other PN-150 and PN250 type relays. 18 Coils Switch (S2) In parallel position, the A and B relay coils are placed in parallel. In the single position they are separate. 19 Contact Indicators (L2) Visually indicates the relay's contact configuration and when they are open or closed. 3-6 SM6468 UNION SWITCH & SIGNAL Table 3-1. DC Relay Test Stand, Controls and Indicators (Cont'd) REF ITEM FUNCTION 20 Relay Mounting Base PN-150, PN-150T (Rl) Provides proper position and connections for testing PN-150 and PN-150T style relays. 21 Relay Mounting Base PN-150P, PN-lSOBL (R2) Provides proper position and connections for testing PN-150P and PN-150BL style relays. 22 F/H/B Jacks used with TIMER switch (23) to provide access to set of front, heel, and back contacts. 23 TIMER Switch In OFF position, voltage is fed to lights in column 1, Rows D and E, to light the lights. In TIMER position, voltage is removed to allow flash rate, on-time, and timing measurements to be made. 10 0 0 0 0 0 I ~0001 10 0 00 0 0 I 10 0 0 0 0 0 I ~0001 6FB B A Figure 3-3. ~0001 10 0 0 0 0 0 I 10 0 0 0 0 0 I ~0001 10 0 0 0 0 0 I Basic Contact Indicators Configuration 3-7 SM6468 UNION SWITCH & SIGNAL 3.6 TESTS 3.6.1 Biased Relay Performance Tests The following procedures determine the Drop-Away (Release), Pickup, and Working values of PD-1 types of biased neutral relays. 3.6.1.1 Recommended Test Equipment Power Supply 0-40Vdc DC Voltmeter DC Ammeter DC Relay Test Stand or similar test setup per Figure 3-1. 3.6.1.2 Test Setup. When a DC Relay Test Stand is used, the following procedure creates the test setup required. When the test stand is not used, the test setup shown in Figure 3-1 must be created. The non-test-stand setup can use the rack mounted plug coupler/relay but all system wiring connections must first be removed from the plug coupler. All test connections can then be made to the rack mounted plug coupler. In the following test stand setup procedure, the item numbers are those used on Figure 3-2: a. Ensure the AC POWER switch (4) and TIMER switch (23) are set to OFF. b. Ensure the power switch on the de power supply is set to off, and adjust its output voltage control to the OV output position. NOTE As a general rule when testing relays, such as the PD-1 relays, an ammeter is used to test relays with a coil resistance under 100 ohms, and a voltmeter is used to test relays with a coil resistance over 100 ohms. c. Using test leads, connect either the de voltmeter or ammeter (per above Note) to both the power supply output and the relay coil block jacks A+/A- (8), observing the correct polarity. NOTE The above connections are for single coil relays. For double coil relays, whose coils are wired in series, the meter is connected to the A+ and Bjacks with A- and B+ jacks jumpered. 3-8 SM6468 UNION SWITCH & SIGNAL d. Set the PN-150BL/PN-150P switches (17) to OFF (center). e. Set the COILS switch (18) to the SINGLE position. f. Set the PN-250 LIGHT SELECTION SWITCH (7) to the 1 position. g. With the PD-1 Plug Coupler Adapter seated on a flat surface, insert its cable's PN-250 frame into the PN250B base on the test stand. h. Insert the PD-1 relay to be tested into the Plug Coupler Adapter. i. Set the AC POWER switch (4) to ON and the de power supply to on. j. Set the Coil Polarity switch (9) to the NORMAL (up) position. k. Set the PN-250 switch (2) to the WITH TEST JACK position. 3.6.1.3 Biased Relay Test Stand Procedure. a. Slowly adjust the power supply output control to increase the output, as indicated on the de voltmeter or ammeter, as appropriate, to Charge the relay. (The Charge value is four times the relay's working value, which is specified on the relay's Application Information Sheet.) The Contact Indicators should change from those lit in Figure 3-3A to those shown lit in Figure 3-3B. b. Insert a "stick" into the front test jack. Observe the relay deenergizes (Figure 3-3A). c. Remove the "stick" and observe the relay energizes (Figure 3-3B). d. Set the Coil Polarity switch (9) to the REVERSE position and observe the relay deenergizes. e. Set the Coil Polarity switch to the NORMAL position and observe the relay again energizes. f. Slowly adjust the de power supply controls to reduce the output until the relay deenergizes. Note the value indicated on the meter. This is the Minimum Release (DropAway) value, and should not be less than the InService Application Limit value specified on the relay's Application Information Sheet. g. Further reduce the power supply output, if necessary, until the relay armature rests on the permanent magnet extension. Note the value indicated on the meter. This 3-9 SM6468 UNION SWITCH & SIGNAL is the Minimum Full Release (Drop-Away) value, and should not be less than the In-Service Application Limit value specified on the relay's Application Information Sheet. h. Using the de power supply controls, reduce the output to zero. Then set the Coil Polarity switch (9) to the OFF position for 1 second, and then move it back to the NORMAL position. i. Slowly increase the power supply output until the relay energizes (stop pin closes against the pole face). Note the meter value. This is the Pickup Maximum value and should not be greater than the Inservice Application Limit value specified on the relay's Application Information Sheet. 3.6.1.4 a. Biased Relay Test Without Test Stand. Refer to paragraph 3.5, and create test setup per Figure 3-1. Proceed as follows: Set switch Sl to Normal. NOTE As a general rule when testing relays, such as the PD-1 relays, an ammeter is used to test relays with· a coil resistance under 100 ohms, and a voltmeter is used to test relays with a coil resistance over 100 ohms. b. Turn on the de power supply. c. To Charge the relay, observe the meter per the above Note, and slowly adjust the power supply output control to increase the output to four times the relay's working value, which is specified on the relay's Application Information Sheet. The Contact Indicators should change from those lit in Figure 3-3A to those shown lit in Figure 3-3B. Note the relay stays energized as the output is increased. d. Set switch Sl to Reverse. Observe the relay deenergizes. e. Set switch Sl to Normal. Observe the relay energizes. f. Slowly adjust the de power supply controls to reduce the output until the relay deenergizes. Note the value indicated on the meter. This is the Minimum Release (DropAway) value, and should not be less than the InService Application Limit value specified on the relay's Application Information Sheet. g. Further reduce the power supply output, if necessary, until the relay armature rests on the permanent magnet extension. Note the value indicated on the meter. This 3-10 SM6468 .,· UNION SWITCH & SIGNAL is the Minimum Full Release (Drop-Away) value, and should not be less than the In-Service Application Limit value specified on the relay's Application Information Sheet. h. Using the de power supply controls, reduce the output to zero. 1. Slowly increase the power supply output until the relay energizes (stop pin closes against the pole face). Note the meter value. This is the Pickup Maximum value and should not be greater than the In-Service Application Limit value specified on the relay's Application Information Sheet. 3.6.2 Slow Release (Drop-Away) Relay Test A slow release PD-1 relay is a biased relay. Its release, pick-up, and working values are tested in the same manner described in paragraph 3.6.1. Additionally, the release time must be checked, as described in the following procedure. As with the biased relay tests, the slow release timing can be checked with or without the de relay test stand. Both ways are described in the following paragraphs. 3.6.2.1 Recommended Test Equipment. DC Relay Test Stand 0-40Vdc Power Supply DC Voltmeter DC Ammeter Time Interval Meter US&S 911A NOTE Release Time is the time from opening of the relay coil circuit until the front contacts open. In performing each check of release time, the circuit shall first be opened and the voltage then be brought up from zero to the value specified, but not beyond. 3. 6. 2. 2 Slow Release Test with Test stand. a. With the relay mounted as described in paragraph 3.6.1.3 upon conclusion of the biased relay tests, set the TIMER switch (23) to the TIMER position (down). b. Using a Time Interval Meter (TIM) US&S Model 911A, disconnect the jumper leads from the A+/A- jacks (8) and connect them to the corresponding EXTERNAL POWER jacks (+) and(-) on the rear of the TIM, as shown in Figure 3-4. 3-11 SM6468 UNION SWITCH & SIGNAL c. Connect the TIM COIL jacks (Figure 3-5) to relay coil jacks A+/A- (8) (red to A+ and black to A-). d. Connect the TIM CONTACTS jacks across the F and H jacks (22) . e. On the TIM, set the START/STOP switch to the STOP position and adjust the power supply output from zero up to the pick-up value specified on the relay's Application Information Sheet, but not beyond. Leave the power on the coil and proceed to the next step. US&S 911A TIME INTERVAL METER POWER SUPPLY JUMPER + + + Figure 3-4. CONTACTS OPerating Time Measurement, Test Setup 0 PICK-UP 0 PU DROP·AWAY 0 START 0 STOP ON 0 OFF DA 0 RELAY CONTACTS Figure 3-5. 0 ® COIL 8 0 CURRENT/ VOLTAGE SET Time Interval Meter, US&S 911A, Front Panel 3-12 SM6468 UNION SWITCH & SIGNAL f. On the TIM, set the START/STOP switch to the START position, and when the relay deenergizes (front contacts open), note the release time on the TIM. The time should not be less than the release time specified on the relay's Application Information Sheet. 3.6.2.3 Slow Release Test Without Test Stand. a. After completing the biased relay tests per paragraph 3.6.1.4, connect the relay into the test circuit shown in Figure 3-4. b. On the TIM (Figure 3-5), set the switches as follows: 1. PICK-UP/DROP-AWAY switch to the DROP-AWAY position. 2. START/STOP switch to the STOP position. 3. ON/OFF switch to the ON position. c. Set the START/STOP switch to the START position. The display will start timing, then stop, and the DA indicator will light when the relay drops. The value should not be less than the release time specified on the relay's Application Information Sheet. 3.6.3 Slow Pick-Up Relay Test A Slow Pick-Up PD-1 relay is also a biased relay. Its release,pick-up, and working values are tested as described in paragraph 3.6.1. Additionally, the pick-up time must be checked, as described in the following paragraphs. As with the biased relay tests, the slow release timing can be checked with or without the de relay test stand. Both ways are described in the following paragraphs. 3.6.3.1 Recommended Test Equipment. DC Relay Test Stand 0-40Vdc Power Supply DC Voltmeter DC Ammeter Time Interval Meter US&S 911A NOTE Pick-Up Time is the time from closing of the relay coil circuit until the front contacts close. There shall be a minimum of series resistance in the circuit, and the specified voltage shall be measure with the circuit closed. 3-13 SM6468 UNION SWITCH & SIGNAL 3.6.3.2 Slow Pick-Up Test With Test Stand. a. With the relay mounted as described in paragraph 3.6.1.3 upon conclusion of the biased relay tests, set the TIMER switch (23) to the TIMER position (down). b. Using a Time Interval Meter (TIM) US&S Model 911A (Figure 3-5), disconnect the jumper leads from the A+/Ajacks (8) and connect them to the corresponding EXTERNAL POWER jacks (+) and(-) on the rear of the TIM, as shown in Figure 3-4. c. Connect the TIM COIL jacks (Figure 3-5) to relay coil jacks A+/A- (8) (red to A+ and black to A-). d. Connect the TIM CONTACTS jacks across the F and H jacks ( 22) . e. On the TIM, set the START/STOP switch to the STOP position and the DROPAWAY/PICKUP switch to the PICKUP position. Set the power switch to the ON position. f. On the TIM, set the START/STOP switch to the START position, and when the relay energizes (front contacts close,) note the pick-up time on the TIM. The timne should be not be less than the pick-up time specified on the relay's Application Information Sheet. 3.6.3.3 slow Pick-up Test without Test stand, a. After completing the biased relay tests per paragraph 3.6.1.4, connect the relay into the test circuit shown in Figure 3-4. b. On the TIM (Figure 3-5), set the switches as follows: 1. PICK-UP/DROP-AWAY switch to the PICK-UP position. 2. START/STOP switch to the STOP position. 3. ON/OFF switch to the ON position. c. Depress the CURRENT/VOLTAGE SET pushbutton on the TIM and charge the relay in the normal direction as described in paragraph 3.6.1.3 step a, then reduce the voltage to that specified in step i. d. Set the START/STOP switch to the START position. The display will start timing, then stop, and the PU indicator will light when the relay picks. The value should not be less than the relay's pick-up time specified on the relay's Application Information Sheet. 3-14 SM6468 UNION SWITCH & SIGNAL 3.6.4 Magnetic Stick Relay Test 3.6.4.1 Recommended Test Equipment. DC Relay Test Stand 0-40Vdc Power Supply DC Voltmeter DC Ammeter 3.6.4.2 a. Magnetic Stick Relay Test With Test Stand. Create test setup as follows (see Figure 3-2 for item locations) : 1. Ensure that the AC POWER switch (4) and TIMER switch (23) are set to OFF. 2. Ensure the de power supply is off and its controls set for zero output. NOTE As a general rule when testing de relays, such as the PD-1 relays, an ammeter is used to test relays with a coil resistance under 100 ohms, and a voltmeter is used to test relays with a coil resistance over 100 ohms. 3. Using jumpers, connect the de voltmeter or ammeter per the preceding Note, to both the de power supply output and the relay coil jacks A+/A- (8), observing correct polarity. 4. Set the PN-150BL/PN-150P switches (17) to the OFF (center) position. 5. Set the COILS switch (18} to the SINGLE position. 6. Set the PN-250 LIGHT SELECTION switches (7) to the 1 position. 7. With the PD-1 Plug Coupler Adapter seated on a flat surface, insert its cable's PN-250 frame into the PN250B base on the test stand. 8. Insert the PD-1 relay to be tested into the Plug Coupler Adapter. 9. Set the AC POWER switch (4) to ON and the de power supply to on. 10. Set the Coil Polarity switch (9) to the REVERSE (down} position. 3-15 SM6468 UNION SWITCH & SIGNAL 11. Set the PN-250 switch (2) to the WITH TEST JACK position. b. Test the relay as follows: 3.6.4.3 1. Slowly adjust the power supply output control to increase the output, as indicated on the de voltmeter or ammeter, as appropriate, to Charge the relay. (The Charge value is four times the relay's working value, which is specified on the relay's Application Information Sheet.) The Contact Indicators should change from those lit in Figure 3-3A to those shown lit in Figure 3-3B. 2. Insert a "stick" into the front ::est jack. Observe the relay and lights do not cha~-_ge condition. 3. Remove the "stick" and observe the relay does not change. 4. Set the Coil Polarity switch (9) to the NORMAL position and observe the relay armature again reverses position (bottom contacts close). 5. Set the Coil Polarity switch to the REVERSE position and observe the relay armature again reverses position (upper contacts close). 6. Reduce the de power supply output to zero and set the Coil Polarity switch to NORMAL. 7. Slowly increase the de power supply output until the relay armature reverses position and note the value. It should be between the Maximum and Minimum Pick-up and Working values. 8. Reduce the power supply output to zero and set the Coil Polarity switch to REVERSE. 9. Slowly increase the de power supply output until the relay armature reverses position. Note the value indicated on the meter. It should not be more than the Pick-up In-Service Application Limit value specified on the relay's Application Information Sheet. Magnetic stick Relay Test without Test stand. a. Create test setup as shown in Figure 3-2: 1. Ensure that switch Sl is set to Reverse. 2. Ensure the de power supply is off and its output set to zero. 3-16 SM6468 UNION SWITCH & SIGNAL NOTE As a general rule when testing de relays, such as the PD-1 relays, an ammeter is used to test relays with a coil resistance under 100 ohms, and a voltmeter is used to test relays with a coil resistance over 100 ohms. 3. Slowly adjust the power supply output control to increase the output, as indicated on the de voltmeter or ammeter, as appropriate, to Charge the relay. (The Charge value is four times the relay's working value, which is specified on the relay's Application Information Sheet.) 4. Reduce the power supply output to zero and set Sl to Normal. b. Test the relay as follows: 1. Slowly increase the de power supply output until the relay armature reverses position and normal (bottom) contacts close. Note the value. It should be no greater than the Pick-up Maximum In-Service Application Limit value specified on the relay's Application Information Sheet. 2. Reduce the power supply output to zero and set Sl to REVERSE. 3. Slowly increase the de power supply output until the relay armature reverses position and reverse (upper) contacts close. Note the value. It should be no greater than the Pick-up Maximum In-Service Application Limit value specified on the relay's Application Information Sheet. 3.6.5 Switch Overload Relay Performance Test The Switch Overload PD-1 relay cannot be tested usinq the DC Relay Test Stand. 3.6.5.1 Recorrunended Test Equipment. Power Supply, 0-40VDC DC Arruneter, 0-25A Heavy duty SPST switch Power Resistor, 1 ohm, 200W Stopwatch, capable of measuring 15 seconds with 0.1 sec accuracy 3.6.5.2 os Relav Test Procedure. Test the operating characteristics of the switch overload relay as follows: 3-17 SM6468 UNION SWITCH & SIGNAL + DC SUPPLY + OPEN O SHORT S1 SWITCH OVERLOAD RELAY UNDER TEST DC SUPPLY =HP6434B A = DC AMMETER (0-25 MIN) S1 = HEAVY DUTY SWITCH R = POWER RESISTOR Figure 3-6. Switch Overload Stick Relay, Test Setup a. Connect the test setup as shown in Figure 3-6. b. Set the power supply output voltage control to O volts. c. Set switch Sl to the Short position. d. Adjust the de power supply output control to obtain a current measurement equal to the Operating Time Amps specified on the relay's Application Information Sheet. e. Using a stopwatch to make the time measurement, simultaneously set switch Sl to the Open position and start the stopwatch. f. Stop the watch the instant the overload relay energizes. Also, remove power as quickly as possible. The time should be in seconds within the Operating Time specified on the relay's Application Information Sheet. 3.6.6 Flasher Relay Performance Test The PD-1 Flasher relay is a biased relay inserted into a rear service plug coupler, that is equipped with a rear mounted octagonal socket into which a solid-state relay driver flashing unit is installed. The PD-1 Flasher Relay cannot be tested using the DC Relay Test Stand. 3-18 SM6468 UNION SWITCH & SIGNAL 3.6.6.1 Recommended Test Equipment Power Supply, 0-40Vdc SPST switch Electro-mechanicalcounter Counter Stopwatch 0.1 second accuracy Simpson TS-111 On-Time Meter 3.6.6.2 Flasher Test Procedure. a. With the power supply off, connect the relay under test and the required test equipment as shown in Figure 3-7. b. With the Sl switch in its Off position, turn the power supply on, and slowly increase the output until the flasher starts to operate. The voltmeter should indicate between 10-18V de. c. Simultaneously, set switch Sl to its On position and start the stopwatch. d. At the end of 3 minutes, set switch Sl to Off. e. Divide the counter indication by 3 to obtain a pulsesper minute reading. The reading should be between 41 and 45. f. With switch Sl set to Off and the flasher operating, connect an on-time meter between a heel and front contact pair and measure the on-time. Note this measurement. OFF H ----------11e----_;_ ON + POWER SUPPLY F (FRONT) (HEEL v M1 + Left side looking from front) FLASHER UNDER TEST (Right side looking from front) Figure 3-7. + COUNTER Flasher Relay, Test Setup 3-19 SM6468 UNION SWITCH & SIGNAL g. Connect the on-time meter between a heel and back contact pair and measure the on-time. Note this measurement. h. The two measurements should be within 20% of each other. 3.6.7 Lightout Relay Test The PD-1 Lightout Relay cannot be tested on the DC Relay Test Stand. 3.6.7.1 Recommended Test Equipment. Variable transformer (Variac) Tl Filament transformer T2 AC ammeter Resistor 120Vac, 60Hz input 12Vac, 60Hz secondary 0 - SA minimum 4 ohms 3.6.7.2 Lightout Relay Test Procedure. Connect test circuit, as shown in Figure 3-8, and proceed as follows: I WARNING Voltage and current dangerous to life are present. Use one hand to make connections. a. Set switch Sl to the Off position. b. Set Variac output control to the minimum setting. c. Connect circuit to 120Vac, 60Hz line. d. Set switch Sl to the On position. ~,_O_F_F_ __, ON + R _...._._. 120 VAC, 60 HZ (ISOLATED LINE) T2 (12 VAC) -R LIGHT·OUT RELAY UNDER TEST Figure 3-8. Lightout Relay, Test Setup 3-20 SM6468 UNION SWITCH & SIGNAL e. Adjust Variac output control to Charge the relay until the ammeter indicates four times the Working value as specified on the relay's Application Information Sheet. The relay energizes. f. Reduce the Variac control setting until the front contacts open. Note the ammeter indication. It should be no less than specified on the relay's Application Information Sheet. g. Further reduce the Variac output to zero and then open the circuit momentarily. h. Increase the Variac output until the armature completes its pick-up motion and closes against the pole piece. i. Note the ammeter indication. It should be no greater than the Maximum Pick-up In-Service Application Limit specified on the relay's Application Information Sheet. 3-21 SM6468 UNION SWITCH & SIGNAL APPENDIX APPLICATION INFORMATION SHEETS A.1 INTRODUCTION This Appendix contains PD-1 relay Application Information Sheets. Each Application Information Sheet contains the following information for its related PD-1 relay: a. Type of Relay b. Relay Part Number c. Quantity and Type of Contacts d. Relay Coil Resistance e. Plug Coupler Part Number and Type of Service (Front or Rear) f. Contact Data {Application, Max. Rating Volts, Max. Rating Amps) g. Operating Characteristics: 1. Operating Parameters (Volts and Amps for Normal, Min. and Max.) 2. Operating Time (Pick-Up and Release Times) 3. Factory Standard Calibration Values (Drop-Away, Pick-Up, and Working) 4. In-Service Application Limits (Pick-Up and DropAway) 5. Operating Temperature Range h. Contacts Arrangement i. A.2 Notes TYPES OF PD-1 RELA VS This Appendix contains Application Information Sheets for the following types of PD-1 relays: A-1 SM6468 UNION SWITCH & SIGNAL a. Ordinary Acting, Biased Neutral, Low Voltage (Table A-1) b. Ordinary Acting, Biased Neutral, Low Voltage Front, Heavy Duty Back (Part No. 99255565) c. Ordinary Acting, Biased Neutral, Low Voltage, Car Carried (Part No. 99255675) d. A.3 Ordinary Acting, Biased Neutral, High Voltage Front, Low Voltage Back (Part No. 99260147) e. Ordinary Acting, Biased Neutral, High Voltage Front and Back (Part Nos. 99260389, 99260390, and 99260400) f. Slow Release, Biased Neutral, High Voltage (Part Nos. 99255103, 99260501, 99260502, and 99275882) g. Overload (Part Nos. 99275015 and 99275607) h. Flasher, Biased Neutral, Heavy Duty Front and Back (Part Nos. 99260389 and 99275037) i. Light Out, Biased Neutral, Low Voltage (Part Nos. 99275048 and 99275838) J. Magnetic Stick, Biased Neutral, Low Voltage (Part Nos. 99215070, 99275180, and 99275334) k. Power Off, Biased Neutral (Part Nos. 99260389 and 99275257) l. Magnetic Blow-Out, Biased Neutral (Part Number 99275860) ABBREVIATIONS The Abbreviations used on the Application Information Sheets are defined below: MEANING ABBREVIATION AG B F FB H HD HV N PO R s Silver Back Contact Front Contact Front-Back Heel Contact Heavy Duty Contact High Voltage Contact Normal Contact (Magnetic Stick Relay) Power Off Reverse Contact (Magnetic Stick Relay) Silver A-2 SM6468 UNION SWITCH & SIGNAL Table A-1. Ordinary Acting, Biased Neutral, Low Voltage PD-1 Relays CONTACT TYPES PART NO. COIL OHMS CONTACT QTY. PLUG COUPLER TYPE 99255004 500 6FB Front F (Carbon Silver/Silver) B (Silver/Silver) 99255092 125 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255114 500 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255180 200 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255290 200 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255499 2.0 6FB Front F (Carbon Silver/Silver) B (Silver/Silver) 99255686 800 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255719 3500 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) 99255893 500 6FB Rear F (Carbon Silver/Silver) B (Silver/Silver) A-3 SM6468 UNION SWITCH & SIGNAL This page left intentionally blank A-4 SM6468 RELAY EHGIN!:ERIHO APPLICATIOH IHFOJlMATIOH SBEET THIS SHEET PROVIDES GENERAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERATING CH.A.RACTERISTICS FOR THIS RELAY, TYPE OF RELAY. ?0-1 Ord. Acting,Biased Neutral, Low Volt. INDEX l!:lt RELAY PART NUMBER. 99255004 DRAWING NUMBER SCS59 REV-C QTY, AND TYPE OF CONTACTS: .§!.i FICarbon Silver to Silver) BISLlver to Silveri lJQ WIRE SIZE, RELAY COIL RESISTANCE. iQQ_ OH.MS, ( J SHELF MOUNT J REAR SERVICE { 13,000 TURNS. PLUG COUPLER PART NO, {XJ FRONT SERVICE 7467S03SHI,i { J TRAIN CARRIED CONTACT DATA APPLICATION RATING VOLTS, KAX. RATING AMPS. r1 [XJ (S) SAFETY. UP TO 30 4 MAX. r-L (HD) HEAVY DUTY. UP TO 30 10 {l OPERATING CHARACTERISTICS. OPERATING PARAMETERS OPERATING TIME AT NORMAL VOLTAGE {XJ AMPS. { I i FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. f HIGH VOLTAGE. CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 500 Ohm RIGHT SI Of ll.:..Q voe AMPS MIN. ~ voe AMPS MAX. ..u.Q VDC AMPS INTERMITTENT i (HV) 10 (-) COII.f"Y"'\..t +) COIL 9 6£: IS) SH 1s1 PICK-UP !l.,_l_l SECOND a 6H SH RELEASE Q.dll SECOND 7 68 SB rs) DROP-AWAY ~ VDC AMPS 6 4F PICK-UP ~ voe AMPS s 4H ~H WORKING ~ VDC AMPS 4 48 38 ...:L.ll voe 0.0143 AMPS 3 2[ DROP-AWAY MIN • .L.li VDC 0. 0027 AMPS 2 2H PICK-UP MAX • OPERATING TEMPERATURE RANGE. -40°F to +185°F. l a rs1 3P' CS} lF I SI lH U! NOTES l. 2. J, This relay shall be tested on a periodic basis, not exceeding 2 years or current FAA-required testing interval. When relay operate out aide the inservice application limit• value, it shall be reconditioned aa per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derata 60\ for inductive and 40\ for motor load. A-5 RELAY ENGINEERING APPLICATION INFORMATION SHEET THIS SHEET PROVIDES GENERAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERATING CHARACTERISTICS FOR THIS RELAY. TYP£ Ofr PD·l Ord. Acting 1Biased Neutral L.V. 99255092 DRAWING MJMSER, i.uMBER. Altl.AY, flELA Y PART Ra.AY con. RESISTANCE. ~UCI COUPLER F'Nff NO. COIL. ll-,10!:X C-M F[Carbgn Silver to 5ilverl B(SiJver to SiJver) ..fil:L.. QTY. AMO TYPE OF CONT A~TS. 5CS03 REV. D _ ...1... 2s"-- ()t,l,,fS, _ . ,. .z. .z_ . WIRE SIZE, 74655002CM [XJ ...,. IIIMC& D P'IICINI' IIIMCS - - - - - fil (S) SAFETY. 6, D ..._. fCQff O T1IAM zoo ----- c..- - - - - - CONT ACT DAT A '-"l.lCA TIOH MAX. RA TINO VOL TS. 0 UP TO 30 - . 12,0 3,0 { -. AS VIEWED FROM MM LO'T IIIC /2/; Jl. Nff 1o <->co1L../"'"'Y-y-'\_ •>coll.· voe _ __ y DC - - - N4'S INHJMTTIHT, 9 SCCCIND a IIKUAM~ KC'ONI) 7 l'tat4' __J2.j21_ { --,.WAT,. FACT ORY ST AHOAAO CALIBRATION VALUE. CONTACTS AR~NGEMENT "DC 120 ' MAX. OPERA TING TIME AT~ NORMAL VOLTA<K. L.:J AMPS, 0 (HY) HIGH VOLT ACIC. ;o OPERA TING CHARACTERISTICS. OPERATING PARAMETERS 0 UP TO 30 ... MAX. RA TINO AMPS. (HD) HEAVY DUTY. { l'tCII~ IHSERVICE APPICA TIOH { LIMITS. 1.0 3.0 3.0 3.30 0.67 l'tat4' MAX. OfllOl'-AWAT ..._ Of"EIIA TING TD-P£RA TURIC RAHCK. ·'40• F TO _6f _(~ ~- ~.l _6H_ - SlL __ -2! __ SB V, DC - - - N 4 ' 9 e .JE lSJ Y,DC - - - N . s e 4H V.DC ._. ... V.DC ~ 3 v.cc~...,... 2 •1815• F. --4B - ]~-(~ .21:l. __ J~-- lF_(S}. 3H 3B ---- y: _c~1. U'--lB__ - NOTES I. Z. 3. THIS "El.AT SHALL 111€ TESTED OH A PEIUOOIC BASIS, HOT !XCHOINO I Y!AIIS 011 CUll .. !NT l"M•IUOUllltO TESTING NTEIIVAl., WHOf ll[LAY OPtMT! OIJT SIO[ THE IHSEltVICt APf>L ICATION LIMITS VA.WE IT SHALL IE ft!:f:gNOfTIOH£D AS PEii PO-I IIELAY SHOl'l"tHO l'ROCEDUII! ANO CAUI .. ATE TO l"ACTOIIT sfANOAIIO CAI.IIMTION V41.U(. CONTACT AMP!II! IIATINO IS BASED ON RESISTIVE LOADS ONl.Y, DtllATE 10 '% l'QII INDUCTIVE ANO ~0% l"Ofl MOTOII LOAD, A-6 RELAY ENOIH!!ERINO APPLICATION INFORMATION SKEZ'r TRIS SHEET PROVIDES ODR!RAL INFORMATION COHCERNIHO TSE COH'I'ACTS, COIL AND OPERATING CKARACTERISTICS roR TBIS RELAY, TYPE OF RELAY. P0-1 Slow Release Biased Neutral Low Volt. RELAY PART NUMBER. 99255103 DRAWING NUMBER SCS06 REV-E QTY. ANO TYPE OF CONTACTS: .§1:11. FICarbon Silver to Silver) BISilver to Silvwr) RELAY COIL RESISTANCE, 200 i l l WIRE SIZE, OH.HS, [X) REAR SERVICE INDEX B-E 6.500 TURNS. ( I SHELF MOUNT 7465~002 PLUG COUPLER PART NO. [ l TRAIN CARRIED I FRONT SERVICE ( CONTACT DATA APPLICATION [X) MAX. RATING VOLTS, MAX. RATING AMPS, [ I (HO) HEAVY DUTY, (S) SAFETY, UP TO 30 4 (J OPERATING CHARACTERISTICS. r= OPERATING PARAMETERS MIN. l MAX, OPERATING TIME AT NORMAL VOLTAGE [X) AMPS. ( I PICK-UP AMPS ~ voe AMPS 120 voe AMPS INTERMITTENT 10 (-)COI~(+)COIL 9 6F IS) SF IS I SECOND 8 6!:i St! SECOND at l2V 7 6B SB j OROP-.-A< __l..:....Q voe AMPS 6 4F PICK-UP _Ll voe AMPS s 4!:f 3H WORKING _Ll voe AMPS 4 48 38 FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. voe RL.LEASE Q..:.2.._ HIGH VOLTAGS. CONTACTS ARRANGZK!NT AS VIEWED FROM REAR LEFT SIDE 200 Ohm RIGHT SIDI 12.0 Jl.....ll (HV) UP TO 30 10 i PICK-UP MAX, -1..:..ll voe 0.036 AMPS 3 n CROP-AWAY MIN • .L..ll voe 0.067 AMPS 2 2H OPERATING TEMPERATURE RANGE, -40°F to +1SS°F. l 28 1s1 IS! 3F cs I lf [Sl lH U! NOTES 1. 2. 3. Thia relay shall be tested on a periodic basis, not exceeding 2 years or current FRA-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PO-l relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-7 RELAY ENGINEERING APPLICATION INFORMATION Sll!!ET TRIS SHEET PROVIDES GENER.AL INFORMATION CONCERNING THE CONTACTS, COIL CHARACTERISTICS FOR TBIS RELAY. RELAY PART NUMBER. 99255114 DRAWING NUMBER 5CS07 QTY. ANO TYPE OF CONTACTS:~ FICarbon Silver (x I REV-f COIL INDEX li::lt Silver) SfSilver tl.Q WIRE SIZE, RELAY COIL RESISTANCE • .2QQ_ OHMS, OPERATING Volt. TYPE OF RELAY. P0-1 Ord. Acting.Biased Neutral, Low to AN'D REAR SERVICE 746550021:[I.i to Silver) 13.000 TURNS. [ l SHELF MOUNT PLUG COUPLER PART NO. [ l TRAIN CARRIED J FRONT SERVICE ( CONTACT DATA APPLICATION RATING VOLTS. MAX. RATING AMPS. (x l MAX. ( J (HO) HEAVY DUTY. (S) SAFETY. UP TO 30 4 r1 (HV) HIGH VOLTAGZ. UP TO 30 10 CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 500 Ohm RIGHT SIDI OPERATING CHARACTERISTICS. 12.0 voe AMPS MIN. ....§..:.a. voe AMPS MAX. liQ voe AMPS INTERMITTENT ) NO= OPERATING PARAMETERS OPERATING TIME AT NORMAL VOLTAGE [xl A.MPS. ( l i i FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. j 10 (-)COI~+)COIL 9 6F rs1 SH (s l PICK-UP 2-,.ll SECOND 8 6!:i SH RELEASE 0.02 SECOND 7 68 SB CROP-AWA< ~ voe AMPS 6 4F IS) 3[ ISi PICK-UP ~ voe AMPS 5 4!:i 3t! WORKING ~ voe AMPS 4 48 38 hll voe O.OU3 AMPS 3 2[ voe O. 0027 AMPS 2 2H PICK-UP IW<. DROP-AWAY MIN. 1. 34 OPERATING TEMPERATURE RANGE. -40°F to +185°F. l a cs1 l[ (5 l lH u NOTES 1. 2. 3. This relay shall .be tested on a periodic basis, not exceeding 2 years or current FAA-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-8 RELAY ~OIH!!ERINO APPLICATION INFOJUCATIOH SKl:Z'l' THIS SHEET PROVIDES GENER.AL INFORMATION CONCERNINO THE CONTACTS, COIL AHD OPERATING CRARACT!RISTICS TOR THIS RELAY, TYPE OF RELAY. P0-1 Slow Piek-Up Biaeed. Neutral Low Volt, RELAY PAltT NUMBER. 99255180 DRAWING NUMBER 5C5l3 BEV-B QTY. AND TYPE OF CONTACTS: ial FtCarbon Silver to Silver) BISi~ver to Silveri RELAY COIL RESISTANCE, 200 i l l WIRE SIZE, OHMS, COIL INDEX~ 6.500 TURNS. [X] REAR SERVICE rJ SHELF MOUNT [ J FRONT SERVICE r1 TRAIN CARRIED ?LUG COUPLER PART NO. CONTACT DATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS. f I (HD) HEAVY DUTY. UP TO JO 10 [XJ (S) SAFETY. UP TO JO 4 r1 OPERATING CHARACTERISTICS. ::~ ' .:: ) OPERATING PA.RA.METERS MAX. OPERATING TIME AT NORMAL VOLTAGE (X] AMPS. [ J FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. l 120 (HV) HIGH VOLTAGE. CONTACTS ~G!MENT ·---·AS VIEWED FROM REAR LEFT SIDE 200 Ohm RIGHT SIO. voe AMPS voe AMPS voe AMPS INTERMITTENT 10 (-)COIL 9 6F C§l SF IS\ (+)COIL PICK-UP 0.75 SECOND 8 6H SH RELEASE 2:..11 SECOND 7 68 SB DROP-AWAY l.:.jQ voe AMPS 6 4F 1s1 3F f S 1 PICK-UP .2..:..QQ voe - - - AMPS s 4H 3H WORKING .2..:..QQ voe AMPS 4 48 38 PICK-UP MAX. 2.:...2..Q. voe 0.049 AMPS J 2F 1s1 lf IS! DROP-AWAY MIN. 1...1.i voe 0.011 AMPS 2 2H lH l l OPERATING TEMPERATURE RANGE, 1 28 HI NOTES 1. 2. 3. Thia relay shall be teated on a periodic baaia, not exceeding 2 years or current FR.A-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor loa~. A-9 RELAY ENGINEERING APPLICATION IHFORMA~IOH SKEET TBIS SBEET PROVIDES GENERAL INFORMATION CONCERNING TBE CONTACTS, COIL AND OPZRATINO CHARACTERISTICS FOR TBIS RELAY, TYPE OF RELAY. P0-1 Slow Pick-Up Biased, Neutral Low Volt. RELAY PART NUMBER. 99255290 OR.AWING NUMBER SC523 REV-E QTY, AND TYPE OF CONTACTS: 6FB F(Carbon Silver to Silver} B(Silver to Silver) RELAY COIL RESISTANCE. 200 i l l WIRE SIZE, OHMS, COIL INDEX C-L 6.500 TURNS. [ l SHELF MOUNT [X] REAR SERVICE 74655002 PLUC COUPLER PART NO. [ l TRAIN CARRIED I FRONT SERVICE [ CONTACT DATA APPLICATION MAX. R.ATINC VOLTS. HAX. RATING AMPS. [XJ [ l (HO) HEAVY DUTY. ( S) SAFETY. UP TO 30 [ l (HV) HICH VOLTAGE. UP TO 30 10 4 CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 200 Ohm RIGHT SID OPERATING CHARACTERISTICS. 12.0 voe AMPS MIN. _2..:.Q voe AMPS MAX, ll.Q voe AMPS INTERMITTENT }NOMll OPERATING PARAMETERS OPERATING TIME AT [X) NORMAL VOLTAGE AMPS. ( I FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. 10 (-)CO~+)eOIL 9 6F (~l SF ~ PICK-UP .1....,2Q SECOND 8 6H SH l RELEASE O. 60 SECOND ·7 68 SB ! DROP-AWAY L..L voe AMPS 6 4F IS! 3F IS} PICK-UP i.,_Q_ VDe AMPS 5 4H 31::1 WORKING i.,_Q_ voe AMPS 4 4B 38 PICK-UP MAX, 2.:..2Q voe 0.0495 AMPS 3 2F IS} lF IS} DROP-AWAY MIN. 2.33 voe 0.0116 AMPS 2 2H lH l OPERATING TEMPERATURE RANGE. -40°F to +185°F. 1 a u NOTES 1. 2. 3. rs1 This relay shall be tested on a periodic basis, not exceeding 2 year• or current FRA-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-10 RELAY 1!:NGIH!:!!RINQ APPLICA:t'ION I!ll'OJUCA:t'IOH sn:rr TRIS SHEET PROVIDES O!!H!:RAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERA:t'INO CHARACTERISTICS TOR TRIS R.!:LAY, TYPE OF RELAY. PD-1 Ord. Acting,Biased Neutral. Low Volt. RELAY PART NUMBER. 99255499 DRAWING NUMBER SCSJ4 QTY, AND TYPE OF CONTACTS: 6FB F(Carbon Silver to Silver} BISilver to Silver) l.il WIRE SIZE, RELAY COIL RESISTANCE. 1-:.Q_ OHMS, TURNS. { l SHELF MOUNT l REAR SERVICE { 925 PLUG COUPLER PART NO. CI TRAIN CARRIED (X] FRONT SERVICE 7467SQ§§ CONTACT DATA APPLICATIOM MAX. RATING VOLTS. MAX. RATING AMPS. [XJ (S) SAFETY. UP TO JO 4 [ I (HO) HEAVY DUTY. (I OPERATING CHARACTERISTICS. ) NO=L OPERATING PARAMETERS MIM. l MAX. OPERATING TIME AT NORMAL VOLTAGE [ I AMPS. [X] FACTORY STANDARD CALIBRATIOM VALUE INSERVICE APPLICATION LIMITS. (HV) HIGH VOLTAGE. UP TO JO 10 CONTACTS ARRANCEMJ:HT AS VIEWED FROM REAR LEFT SIDE 2.0 Ohm RIGHT SID: voe 0.680 AMPS voe 0 .170 AMPS voe 1. 70 AMPS INTERMITTEMT 10 (-)COI~(+)COIL 9 6F ( s) SH SECOND 8 6!:I SH RELEASE 0.025 SECOND 7 68 SB PICK-UP Q.,_l.]; ) CROP-AWAY voe 0.057 AMPS 6 4F ISi 3F rs I PICK-UP voe 0.170 AMPS 5 4H 3!:I WORKING voe 0.170 AMPS 4 48 38 2.:...lli voe O.l!jp AMPS 3 ~F voe 0.038 AMPS 2 2H )'ICK-UP KAX. DROP-AWAY MIN. OPERATING TEMPERATURE RANCE, 0.076 -40°F to +1SS°F. 1 28 rs1 lF (5) lH H! NOTES 1. 2. J. rs 1 This relay shall be tested on a periodic basis, not exceeding 2 years or current FAA-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derata 60\ for inductive and 40\ for motor load. A-11 RELAY ENOINEERINO APPLICATION IN1'0RHATIOK SBE~ THIS SHEET PROVIDES OEH!:RAL INFORMATION CONCERNING THE CONTACTS, COIL ANl> OPER.ATIHO CRAJlACTERISTICS FOR THIS Rl!:LAY. TYPE OF RELAY. po-1 O[d. Acting,Biaeed Neutral,W/Low Volt Front & H.O, Baek. RELAY PART NUMBER. 99255565 DRAWING NUMBER 5C532 REV-C QTY. ANO TYPE OF CONTACTS: .§.I.§. RELAY COIL RESISTANCE. 500 FICarbon Silver to Silveri BHOlSilyer to Silver) [ J SHELF MOUNT J REAR SERVICE [ 13 t 000 TURNS. llQ WIRE SIZE, OHMS, PLUG COUPLER PART NO. [ J TRAIN CARRIED [XJ FRONT SERVICE 74675;Jn, CONTACT DATA APPLICATION HAX. RATING VOLTS. MAX. RATING AMPS. [ J (HD) HEAVY DUTY. [XJ (S) SAFETY. [J 4 11.....Q voe AMPS J..,.j_Q voe AMPS 120 voe AMPS INTERMITTENT J"OAAAL HIN. l l FACTORY STANDARD CALIBRATION VALUE (-)COir....../"'"'\..+)COIL 6F IS\ SH Is J SECOND 8 6H 5!:f RELEASE~ SECOND 7 68 IHD) SB PICK-UP O. 25 IHDJ DROP-AWAY L.Q_ voe AMPS 6 4F [Sl 3f {SJ PICK-UP ha.Q. voe AMPS 5 4!f 3!:I 6.50 voe AMPS 4 48 CHP1 JB {HDJ PICK-UP MAX. 7. 15 VDC .0143 AMPS 3 ~F IS) lF {Sl DROP-AWAY KIN. 1..:.1..L voe .0026 AMPS 2 2H lH 1 WORXINC IN SERVICE APPLICATION LIMITS. 10 9 MAX. OPERATING TIME AT NORMAL VOLTAGE CXJ AMPS, (J HIGH VOLTAGE. CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 500 Ohm RIGHT SIDE OPERATING CHARACTERISTICS. OPERATING PARAMETERS (HY) UP TO 30 10 UP TO 30 OPERATING TEMPERATURE RANGE. -40°F to +1SS°F. l ,a CHP> u 1!:fQl NOTES 1. 2. 3. Thia relay shall be teated on a periodic baaia, not exceeding 2 year• or current FAA-required testing interval. When relay operate out aide the inservice application limit• value, it shall be reconditioned aa per P0-1 relay s~opping procedure and calibrate to factor standard calibration value. Contact ampere rating ia baaed on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-12 RELAY ENGIN!:EKINO APPLICATION INFOR.MATIOH SKEET TRIS SHEET PROVIDES GENERAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERATING CRAKACTEKISTICS FOK TRIS RELAY. TYPE OF RELAY. P0-1 fla1het,Biased Neutral.W/Heavy Duty front & COOE INDEX RELAY PART NUMBER, 99255664 DRAWING NUMBER SC526 QTY. ANO TYPE OF CONTACTS: .§.flt F&B HO(Silver to Silver) /.12. WIRE SIZE, RELAY COIL RESISTANCE • .llj_ OHMS, [XJ REAR SERVICE Back, ~ 6 1 700 TURNS. [] SHELF MOUNT 74655026 PLUG COUPLER PART NO. ( ) FRONT SERVICE~~~~~ [ ) TRAIN CARRIED - - - - CONTACT DATA APPLICATION [ J (S) SAFETY. [XJ UP TO JO MAX. RATING VOLTS. MAX. RATING AMPS. 4 (HD) HEAVY DUTY. UP TO 30 10 (] CONTACTS ARRANGEMENT ·---AS VIEWED FROM REAR LEFT SIDE 125 Ohm RIGHT SIDf OPERATING CHARACTERISTICS. OPERATING PARAMETERS r= MIN. l MAX. OPERATING TIME AT [X] NORMAL VOLTAGE AMPS. [ I FACTORY STANDARD CALIBRATION VALUE 12.0 voe AMPS _LlL voe AMPS ll.Q... voe AMPS INTERMITTENT PICK-UP O. 01 I RELEASE 0.04 10 (-) COIL..f"\._I +)COIL 9 6F fRPI SH {HD! SECOND 8 6H SH SECOND 7 6B CHOI SB IHDl DROP-AWAY l.:JL voe AMPS 6 4F tHPJ 3F <HD! PICK-UP L.Q_ voe AMPS 5 4!:{ 3H L.Q_ voe AMPS 4 48 tHQI 38 (HDl PICK-UP MAX. 2:..1.Q_ voe ,02B AMPS 3 2[ lRPl lf IHQI DROP-AWAY MIN. Q....§.1_ voe .0053 AMPS 2 2H lH i WORKING IN SERVICE APPLICATION LIMITS. (KV) HIGH VOLTACZ. OPERATING TEMPERATURE RANGE. -40°:r to +185°:r. 1 28 lRPl u CHO) NOTl!:S 1. Thia relay shall be tested on a periodic baai•, not exceeding 2 year• or current FRA-required teating interval. 2. When relay operate out side the inservica application limits value, it ahall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. 3. contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. 4. When this relay is used with Tranacontrol Relay Driver Style (F.R.O.) Part No. 75335009, it will provide 43-2 flaahe• per minute, starting at 10 voe. •This relay can be replaced by P/N 99260389 A-13 RELAY ENOIN'!!ERINO APPLICATION INFORMATION SBZ~ THIS SHEET PROVIDES GE~JlAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERATINO CHARACTERISTICS FOR THIS RELAY, TYPE OF RELAY. P0-1 Ord, Acting. Biased Neutral. Low Volt RELAY PART NUMBER. 99255675 DRAWING NUMBER~ QTY. ANO TYPE OF CONTACTS:~ FICarbon Silver to Silveri BISilver to Silveri l l i WIRE SIZE, RELAY COIL RESISTANCE. 3500 OHMS, 35,000 TURNS. (J SHELF MOUNT REAR SERVICE PLUG COUPLER PART NO. [ ) FRONT SERVICE [) TRAIN CARRIED [X) (No plug coupler is used on Train carried Relay) CONTACT DATA APPLICATION [ X] MAX. RATING VOLTS. MAX. RATING AMPS. [) ( S) SAFETY. UP TO 30 4 (HO) HEAVY DUTY. UP TO 30 10 [] 1·0= OPERATING TIME AT NORMAL VOLTAGE [ AMPS. [ FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. j 28.0 voe AMPS KIN. 11..:..Q_ voe AMPS MAX. l.[Q_ voe AMPS INTERMITTENT 9 §F cs2WsF ! Sl 121<, 2W PICK-UP 0. 25 I I HIGH VOLTAGE. CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE RIGHT SIDE 3500 Ohm 10 (-)COIL (+)COIL OPERATING CHARACTERISTICS. OPERATING PARAMETERS (HV) SECOND RELEASE Q_,_QL SECOND 8. 6!:i fili_ 7 68 a_ DROP-AWAY i..:...ll voe AMPS 6 4F IS) Jf PICK-UP 17.0 voe AMPS 5 4!:I 1!:i__ WORKING 17.0 VDC AMPS 4 48 a_ rICK-UP MAX. DROP-AWAY KIN. OPERATING TEMPERATURE RANGE. (5) il..:..lQ VDC .005 AMPS 3 2F !Sl lF ...l.:..il VDC .001 AMPS 2 2!:i 1.!:L_ -40°F to +l8S°F. l 2B (S) ll.__ NOTES l. 2. 3. 4. 5. This relay shall be tested on a periodic basi•, not exceeding 2 year• or current FRA-required testing interval. When ielay operate out side the inse~vice application limits value, it shall be reconditioned as per P0-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. All calculations are based on J,500 Ohm coil, 121<, 2 Watt• resistor is connected in parallel to coil. A-14 RELAY ENGINEERING APPLICATION INFORMATION SHEET THIS SHEET PROVIDES GENERAL INFORMATION CONCERNING TBE CONTACTS, COIL AND OPERATING CBAR.ACTERISTICS FOR THIS RELAY. TYPE OF RELAY. PQ-1 Ord. Acting. Biased Neutral, Low Volt RELAY PART NUMBER. 99255686 DRAWING NUMBER~ QTY. ANO TYPE OF CONTACTS:~ FICarbon Silver to Silver) BISilver to Silver) RELAY COIL RESISTANCE. §.QQ_ OHMS, WIRE SIZE, ~ (X) REAR SERVICE 17,500 TURNS. ( J SHELF MOUNT 74655002 PLUG COUPLER PART NO. ( J FRONT SERVICE () TRAIN CARRIED---- CONTACT DATA APPLICATION RATING VOLTS. RATING AMPS. (X) HAX. HAX. () (S) SAFETY. UP TO 30 4 (HO) HEAVY DUTY. UP TO 30 10 () OPERATING CHARACTERISTICS. r=L OPERATING PARAMETERS OPERATING TIME AT NORMAL VOLTAGE (XJ AMPS. ( J FACTORY STANDARD CALIBRATION VALUE IN SERVICE APPLICATION LIMITS. (HV) HIGH VOLTAGE. CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE RIGHT SIDE 800 Ohm 10 (-)COII..J'"\.J+)COIL ll...Q voe AMPS MIN. ..JL.Q... voe AMPS MAX. .llQ... voe AMPS INTERMITTENT 9 6F 1s1 SECOND a 6H SH RELEASE~ SECOND 7 _il.__ SB rICK-UP O. 30 SH rs I I OROP-AWAY l..,_iQ voe AMPS 6 4F PICK-UP ~ VDC AMPS 5 4H 3H WORKING ~ VDC AMPS 4 _!L_ 48 PICK-UP MAX. .[.:.filL voe .ou AMPS 3 2E [SI lF [Sl DROP-AWAY MIN. Ll.Q_ VDC .002 AMPS 2 2H lH l OPERATING TEMPERATURE RANGE. -40°F to +1BS°F. l 2 !} rsJ 3H U! NOTES l. 2. J. Thia relay shall be tested on a periodic baai•, not exceeding 2 year• or current FRA-required testing interval. When relay operate out aide the inaervice application limit• value, it shall be reconditioned as per PD-l relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-15 RELAY ENGIH!:!:RINO APPLICATION INP'ORMATIOH sun TBIS SBEET PROVIDES GEN!:RJU. INFORMATION CONCERNING TBE CONTACTS, COIL AND OPERA.TINO C!IARACTERISTICS FOR THIS R!:LAY. Ord. acting, Biased Neutral. Low Volt TYPE OF RELAY. P0-1 RELAY PART NUMBER. 99255719 DRAWING NUMBER~ QTY. AND TYPE OF CONTACTS:~ F(Carbon Silver to Silveri B(Silver to Silver) tli RELAY COIL RESISTANCE. 3500 OHMS, 35,000 TURNS. WIRE SIZE, {X) REAR SERVICE [ J SHELF MOUNT { ) FRONT SERVICE [XJ TRAIN CARRIED 74675211 PLUG COUPLER PART NO. W/Braclcet CONTACT DATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS. [ XJ [) ( S) SAFETY. UP TO 30 4 (HO) HEAVY DUTY. UP TO 30 10 [) OPERATING CHARACTERISTICS. 2a.o voe OPERATING PARAf{ETERS AMPS OPERATING TIME AT NORMAL VOLTAGE (X] AMPS. ( J FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. l voe I AMPS INTERMITTENT 9 6F IS\ SECOND 8 6H Q....QL SECOND 7 PICK-UP Q...ll RELEASE HIGH VOLTAGE, CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE RIGHT SIDE 3500 Ohm 10 (-)CO~)COIL - - - AMPS llQ... (HV) SF <S l SH 58 DROP-AWAY .2....:.ll voe Fl.MPS 6 4F PICK-UP 11.0 voe - - - AMPS 5 4H WORKING 11.....Q VDC - - - AMPS )PICK-UP MAX, 18.70 voe .0053 AMPS 3 2F ISl lF IS I ( DROP-AWAY MIN, _h.il VDC .001 2 2H lH OPERATING TEMPERATURE RANGE. (Sl JF 1s1 3H 38 AMPS l 28 lB NOTES l. 2. 3. This relay shall be tested on a periodic basis, not exceeding 2 years or current FRA-required testing interval. When relay operate out side the inservice application limits value, it ahall be reconditioned as per P0-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-16 RELAY ENGINEERING APPLICATION INFORMATION SHEET THIS SHEET PROVIDES GENER.AL INFORMATION CONCERNING THE CONTACTS, COIL AND OPERATING CRARACTERISTICS FOR THIS R.!:LAY, TYPE OF RELAY. P0-1 Ord. Acting.Biased ffeytral. Low Volt. RELAY PART NUMBER. 99260147 DRAWING NUMBER 5C596 REV-A QTY. AND TYPE OF CONTACTS: 6F8 F{Silver Graphite to Silver} 81Silver to Silver} RELAY COIL RESISTANCE, 500 INDEX CODE llQ WIRE SIZE, OHMS, (XJ REAR SERVICE H-L 13,000 TURNS, (] SHELF MOUNT 74655002HL PLUG COUPLER PART NO. ( J TRAIN CARRIED FRONT SERVICE CONTACT DATA APPLICATION KAX, RATING VOLTS, MAX. RATING AMPS. FRONT CONTACTS (] [ ] ( S) SAFETY, UP TO .30 4 (HO) HEAVY DUTY, UP TO .30 10 FRONT CONTCTS (HV-S) (XJ (HV) HIGH VOLTAGE, SOVDC/llOV AC lSA OPERATING CHARACTERISTICS, ro= OPERATING PAAAXETERS OPERATING TIME AT NOAAAL VOLTAGE (X) AMPS. ( I FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION [.!HITS. CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE RIGHT SIDE 12.0 \JDC AMPS HIN. -2..:...2. voe AMPS MAX, llQ_ voe AMPS INTERMITTENT 10 (-)COIL...f"'l...J+)COIL HV-s SF 9 6f SECOND 8 6!:f 51:f RELEASE Q...QL SECOND 7 68 SB l'ICK-UP l!...l.l. f°ROP-AWAY L.Q... voe AMPS 6 4f PICK-UP L..L voe AMPS 5 4H 3!:f WORKING L..L \JDC AMPS 4 48 38 PICK-UP MAX, 1..:..1.L voe ,OH3 AMPS 3 2F DROP-AWAY HIN. Ll.L voe .0027 AMPS 2 2!:f r OPERATING TEMPERATURE RANGE. -40°F to +185°F. 1 28 HV-S HV-S HV-s .JF HV-S lf HV-S lH !B NOTES 1. 2. .3. This relay shall be teated on a periodic basis, not exceeding 2 year• or current FRA-required testing interval. When relay operate out aide the inservica application limit• value, it shall be reconditioned as per P0-1 relay shopping procedure and calibrate to factor standard calibration value • Contact ampere t"ating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-17 ltELAY EHOIH!:ERIHG APPLICA~IOH IHFOJlKA~IOH SHEE~ TBIS SBEET PROVIDES O!:Nl!:R.AL INFORMATION CONCER.NINO TBE CONTACTS, COIL AND OPERATING CHARACTERISTICS FOR THIS RELAY, TYPE OF RELAY. PO-t Ord, Acting.Biased Neutral, HV-S RELAY PART NUMBER. 99260389 DRAWING NUMBER 5C641 REV-d QTY. ANO TYPE OF CONTACTS: 6FB F&BISilver Graphite to Silveri RELAY COIL RESISTANCE, PLUG COUPLER PART NO, 112... OHMS, COIL INDEX 1.1:J.. WIRE SIZE, (X] REAR SERVICE [ J FRONT SERVICE *SEE NOTE 141 ( ] ( S) SAFETY. UP TO 30 (] &=1. HV 6 1 700 TURNS. () SHELF MOUNT ( J TRAIN CARRIED CONTACT DATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS, 4 (HD) HEAVY DUTY, UP TO 30 10 OPERATING CHARACTERISTICS. ) NORMAL 1l.:...Q vtlC AMPS MIN, -1.:...Q vtlC AMPS MAX • 11Q.. voe l OPERATING PARAMETERS OPERATING TIME AT NOR.MAL VOLTAGE (XJ AMPS. [ ] FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. ~~~ (XJ (HV) HIGH VOLTAG!, SAFETY UP TO 50 OC/llOV AC 15 CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 125 Ohm RIGHT SIOf 10 AMPS INTERMITTENT (-)COI~+)COIL 9 6F HV-S SF HV-S ) PICK-UP 0.07 SECOND 8 6H l SH SECOND 7 68 HV-s SB HV-S RELEASE O. 04 f l DROP-AWAY .L..Q_ voe AMPS 6 4F HV-S 3F HV-S PICK-UP l.:..Q_ 1/tlC - - - AMPS 5 4H 3H l.:..Q_ 1/tl C AMPS 4 48 HV-s 38 HV-S ) : : : : : : MAX, DROP-AWAY MIN, l.:.lQ_ 1/tlC 0.026 AMPS 3 2F HV-s lF HV-S 9..:..§.L vtlC 0.005 AMPS 2 2H lH OPERATING TEMPERATURE RANGE. 1 28 HV-s lB HV-S NOTES 1. 2. 3. 4. This relay shall be tested on a periodic basis, not exceeding 2 year• or current FRA-required testing interval. When relay operate out aide the inservice application limits value, it shall be reconditioned as per P0-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. -Relay used with PO, Rectifier Unit #788058S has Plug Coupler #74655123. A• Power Off/W Rectifier, Relay operates@ 6/7VAC Drop-Away, 9VAC Pick-Up, Work, -Relay used W/Flasher Relay DrivertFRD}l75JJ5009 has Plug Coupler#7465512J. Aa Flasher Relay it provides 43 ~ 2 Flashes/Hin, starting@ lOvtlC. -Relay used alone as Line Relay has Plug Coupler 174655002. A-18 RELAY ENOIHEERING APPLICATION INFORMATION SB!!T THIS SHEET PROVIDES O!:Hl!!RA.I., INTORMATIOM COMCERHINO THE CONTACTS, COIL AND OPERATIHO CllARACT!RISTICS TOR TBIS RELAY, TYPE OF RELAY. po-1 Ord. Acting.Biased Neutral, HV-5 RELAY PART NUMBER, 99260390 QTY. AND TYPE OF CONTACTS: DRAWING NUMBER~~~~~~ F&B(Silver to Silver) l1J. RELAY COIL RESISTANCE. 11.§._ OHMS, (XJ REAR SERVICE PLUG COUPLER PART NO. COIL INDEX C-3 HQ WIRE SIZE, •SEE NOTE (4) ( J FRONT SERVICE 6 1 700 TURNS. ( J SHELF MOUNT [ J TRAIN CARRIED CONTACT DATA APPLICATION KA:<. RATING VOLTS, MAX. RATING AMPS, [ J [XJ ( S) SAFETY. UP TO 30 4 (HD) HEAVY DUTY. UP TO JO 10 OPERATING CHARACTERISTICS. (HV) HIGH VOLTAC!. SAFETY UP TO 50 DC/llOV AC 15 (] CONTACTS ARRANGEMENT AS VIEWED FROM RZAR LEFT SIDE 125 Ohm RIGHT SI:>! 12.0 voe AMPS HIN. _LQ voe AMPS MAX. 1lQ_ voe AMPS INTERMITTENT ) NO= OPERATING PM>.METERS OPERATING TIME AT NORMAL VOLTAGE (X) AMPS. [ J FACTORY STANDARD CALIBRATION VALUE IN SERVICE APPLICATION LIMITS. 10 (-)CO~+)COIL 9 6f CHO) SF {HOl ) PICK-UP O. 07 SECOND 8 6H sH RELEASE 0.04 SECOND 7 68 IHDl SB I HD l £HR> 3F IHD) ) DROP-AWA, 1..:..Q_ VDC AMPS 6 4F PICK-UP l...:..Q_ voe AMPS 5 4H WORKING l...:..Q_ voe AMPS 4 48 IHDl JB (HOl PICK-UP l<AlC. 1..:..1.Q._ voe 0.026 AMPS 3 2F IHQl u: IHDl DROP-AWAY MIN. Q_,_§,L_ voe 0.005 AMPS 2 2H lH l OPERATING TEMPERATURE RANGE. -40°F to +1as°F. 1 3H 28 <HDl 1 !} IHDJ HOTl!:S 1. 2. 3. 4. This relay shall be tested on a periodic basis, not exceeding 2 year• or current FRA-required testing interval. When relay operate out side the inservice application limits value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derate 60\ for inductive and 40\ for motor load. -Relay used with PO, Rectifier Unit #7880588 has Plug Coupler #7465512JC3. As ?owe Off/W Rectifier, Relay operates@ 6/7VAC Drop-Away & 9VAC Pick-Up & Work. -Relay used W/Flasher Relay Driver(FRD)#75335009 has Plug Coupler#74655123C3. As Flaaher Relay it provides 43 2 Flashes/Hin, starting@ lOVDC. z A-19 REI.A Y ENGINEERING APPLICATION INFOflMA TtON SHEET THIS SHEET PROVID£S GE:NERAL INFOAMAT10N CONCERNING THIE CONTACTS, COIL AHO OPERATING CH-4 RACTERISTICS FOR THIS FlEl.AY. TYP£ OF RELAY. P0-1 Ord. Acting, Biased Neutral, ')<l260400 R£LA Y PART NUMBER. RELAY COIL RESISTANCE. SC64J DRAWING ~MSER. Al;V. r Eroot & BackC51Jver Gcaobte to Silver} CHY} 6fB QTY. ANO TYPE OF CONTACTS: Hi~h Volt Front and Back 13,000 ____ rum.s. _11_3_0__ WIRE SIZE. 5_0_0_ _ _ OHMS, 74655002 Pt..UG COUPt..ER PART NO. O Miii...,.,.., - - - - - - D T'IAIN c, :a: - - - - - - CONT ACT DAT A !:J APPLICATION 0 (S) SAFETY. (HO) HEAVY DUTY. UP TO 30 MAX. RA TING VOL TS. MAX. RA TING AMPS. UP TO 30 UP TO 30 10 ,4 25 OPERATING CHARACTERISTICS. l2,Q fzQ91fL OPERATING PARAME:TERS { ,..., 6 50 120 MAX. OPERA TING TIME AT NORMAL VOLT AGE. AMPS, CJ a FACTORY STANO.ARO CALIBRATION \/ ALUE. (]) (HV) HIGH VOLTAGE. SAFETY {-{-····· -11... CONT ACTS ARRANGEMEN1 AS VIEWED FROM RE.AR 'ii DC l.ll"T . . . MMI' 1D1 10 c->co1t:-froo'l---<•'' V DC - - - voe - - - ...... INTERMITTtH?g .' -AF LJti.- s) 5.F.I. ci.V.:.S SH 0.25 KCOI) e 0.02 68 --- KCCIIG 1 Ji£.HJ:,S) ~B .£f!_V:,S e e _4.f(l{Y_-S) '.l_F1l-\Y-:.S 3H • --- - ..A.I "1{1J,. s ) 2.0 Y. DC l'ta-wt 6. :,Q V, WOllaN9 6. :,O v. DC 7.15 V.DC INSEIIVICE APPICA TION { - - _,. LIMITS. Olft»-AWA'f ...._ OPERA TING TEMPERATURE RANG&. 500 .fl- l. 34 .-..... .-..... DC v. DC .... ~ .0026 .-,.... ·<40• F TO •11!• F. 4H - -- - - -- - 3 .JI Clti.-S > JJ3.!.fiY-...~ l.F 1Ji.Y:.$ 2 _LI!. __ !_H_ - - 1 2B(HV-S) ---- lB(HV-S --- - NOTES I. 2, 3· THIS RELAY SHALL 9! TESTED ON A P!RIOOtC IASIS, NOT EXCEEDING 2 Y!AAS OR cu""!NT F,U· REQUIRE) TEST! NG INTE"VAL, WHEN RELAY OPEl'ATI OUT SIC! THC INHJMCE APPllCATION LIMITS YAW[~ IT SHALL IE R!CONDITIONED AS PER ~I RtUY SHOPP1NG PftOCEDUR! AND CALIBRATE TO FACTO"Y St ANOARO CALl8MT10N VALUE. CONTACT AMP!RE RATING IS BASED ON RESISTIVE LOADS ONLY, DE"AT! 90% FOR INDUCTIVE AND •o 0/. FOR MOTOR LOAD. A-20 RELAY EHOINEERIHO APPLICATION IHFOR.MATIOH SKEET THIS SHEET PROVIDES GENERAL INFORMATION CONCERNINO THE CONTACTS, COIL ANt> OPERATING CRARACTERISTICS FOR THIS RELAY. TYPE OF RELAY. PD-1 Slow Release Biased Neutral High Voltage RELAY PA.RT NUMBER. 99260501 DRAWING NUMBER SC659 REV-F QTY. AND TYPE OF CONTACTS: 6FB F(AG Graphite to Silver). BIAG to AG Gr:aphite) INDEX CODE tl.2. WIRE SIZE, RELAY COIL RESISTANCE. 1-Q.Q_ OHMS, (X] REAR SERVICE ~ 6,500 TURNS. (] SHELF MOUNT 74655156 PLUG COUPLER PART NO. [] TRAIN CARRIED FRONT SERVICE CONTACT DATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS. FRO?,!T CONTACTS {] ( ] ( S) SAFETY. UP TO JO 4 (HO) HEAVY DUTY. UP TO JO 10 . FRONT CONTCTS (HV-S) [XJ (HV) HIGH VOLTAGE. 50VUC/ll0V AC 15A OPERATING CHARACTERISTICS. ro= OPERATING PAAAMETERS CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 200 Ohm RIGHT SI DE ll._ voe AMPS HIN. ~ voe AMPS MAX. 11..:.Q voe AMPS INTERMITTENT 10 9 (-)COIL~+)COIL 6F HY-S SF HV-S 11<,2W OPERATING TIME AT NORMAL VOLTAGE ( AMPS. ( FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. SECOND 8 6tf RELEASE . L l _ SECOND 7 68 HV-S SB HV-S I"ICK-UP !L.iQ itf__ ) DROP-AWAY .L.Q_ voe AMPS 6 4F HV-5 JF HV-S PICK-UP hi_ voe AMPS 5 4H JH WORKING hi_ voe AMPS 4 48 HV-S JB HV-S AMPS J JF ey-s lF HV-S 0.0067 AMPS 2 2H r!CK-UP MAX, DROP-AWA'! HIN. OPERATING TEMPERATURE RANGE. 1..:...1.L vuc ~ voe -40°F to +18S°F. 0.035 1 2~ lH HY-S u fiV-S NOTES 1. 2. J. This relay shall be tested on a periodic basia, not exceeding 2 years or current FRA-required testing interval. When relay operate out side the inservice application limits value, it shall .be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Plug coupler part I 74655156 has built-in capacitor 4100 HFD 50V in series with ohm, SW resistor, to give a minimum total delay drop of J.O sec. A-21 ~r !:NOINEERIHO APPLICATION INFOJUCATIOH SBEZ'r TBIS SKEET PROVIDES OEHEIUU. INFORMATION CONCERHINO TBE CONTACTS, COIL AND OPEKA.TINO Cl!ARACTERISTICS FOR THIS R.!:LAY. TYPE OF RELAY. P0-1 Slow Release RELAY PART NUMBER. 99260502 Biased Neutral High Voltage OR.AWING NUMBER .2l1l QTY. AND TYPE OF CONTACTS: INDEX CODE C-5 f(Silver to Sllverl HO i l l WIRE SIZE, RELAY COIL RESISTANCE. l l i _ OHMS, 6,500 TURNS. ( l SHELF MOUNT (X] REAR SERVICE PLUG COUPLER PART NO. [) TRAIN CAR.RIED FRONT SERVICE CONTACT DATA APPLICATION HAX. RATING VOLTS. KAX. RATING AMPS. FRONT CONTACTS [ J ( S) SAFETY. UP TO JO [X) (HO) HEAV't DUTY. UP TO JO 10 4 FRONT CONTCTS (HV-S) [ l (HV) HIGH VOLTAGE. 50VDe/llOV AC lSA OPERATING CHARACTERISTICS. re= OPERATING PARAMETERS CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 200 Chill RIGHT SI o: .u_ voe AMPS MIN. _§_,_,a, voe AMPS MAX. 12.0 voe AMPS INTERMITTENT 10 9 (-)COI~(+)COIL 6 f iiP 2..t....!iQ llC, 2W OPERATING TIME AT NORMAL VOLTAGE ( AMPS. [ SECOND 8 6H RELEASE ..L...§__ SECOND 7 66 HO SB HO rICX-UP 0.50 IN SERVICE APPLICATION LIMITS. HD 1-,_Q_ voe AMPS 6 4F HD Jf h.L voe AMPS 5 4H JH WORKING h.L voe AMPS 4 48 HD JB HD PICX-UP !WC, 1..:.J..L VDC O.OJS AMPS 3 3F HQ lf HO DROP-AWAY MIN. Ll.L voe 0.0067 AMPS 2 2H lH rROP-AWA, FACTORY STANDARD CALIBRATION VALUE _lli_ PICK-UP l OPERATING TEMPERATURE RANGE. -40°F to +l8S°F. l 28 HO lB HO NOTES l. 2. 3. Thi• relay shall be te•ted on a periodic ba•i•, not exceeding 2 year• or current FRA-required testing interval. When relay operate out aide the inaervice application limits value, it shall be reconditioned aa per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Plug coupler part I 74655156 haa built-in capacitor 4100 MFD SOV in aeriaa with ohm, SW resistor, to give a minimum total delay drop of 3.0 sec. A-22 REI.Ar ENOINEERIHO APPLICATION IHFOIUCATIOH SBEZ'l' TBIS SBEET PROVIDES OEN'!!R.AL INFORMATION CONCERNING THE CONTACTS, COIL AH'D OPEJtATIHO CIUXACTERISTICS FOR THIS REI.Ar. TYPE OF RELAY. P0-1 Overload RELAY PART NUMBER. 99275015 DRAWING NUMBER 5C51J REV-B QTY. AND TYPE OF CONTACTS: "lH-lB, lHFB Make Before Break, RELAY COIL RESISTANCE. 25/200 OVERLOAD/STICK ( ) REAR SERVICE PLUG COUPLER PART NO. (X) FRONT SERVICE 74675244 CONTACT DATA APPLICATION (] ( ) ( S ) SAFETY'. UP TO JO MAX. RATING VOLTS. MAX. RATING AMPS. 4 F ( J TRAIN CARRIED ro= OPERATING PARAMETERS HIN. MAX. llLU ~ FACTORY' STANDARD CALIBRATION VALUE AMPS DROP-AWAY 150 WATT ( JA MAX.) AMPS INTERMITTENT 120 020 voe OPERATING TIME AT ~7-10 SEC. NORMAL VOLTAGE ( AT AMPS. (X 12 AMPS I voe (X] CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE RIGHT SIDE OPERATING CHARACTERISTICS. WITHOUT O. 046 OHM RES. AMPS B !Palladium-Silver Non-Vital} & ( ) SHELF MOUNT (HO) HEAVY' DUTY. UP TO JO 10 voe £::L INDEX WITH 0.046 OHM RESISTOR 7 ~ + too.Jl. _.]Ji_ 0.1/0.2 voe AMPS 6 PICK-UP J /8 voe AMPS 5 WORKING 3/8 voe AMPS 4 - -- INSERVICE APPLICATI~ICX-UP MAX. J.3/8/8 voe .132/.044 AMPS 3 LIMITS. DROP-AWAY MIN •. 067/.134 voe.002/.0007 AMPS 2 OPERATING TEMPERATURE RANGE. -40°F to +185°F. l NOTES l. 2. 3. Thi• relay ahall be ta•tad on a periodic ba•i•, not exceeding 2 year• or current FRA-required testing interval. When relay operate out aide the inservica application limita value, it ahall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derata 60\ for inductive and 40\ for motor load. A-23 R.!:I.AY ENOINEERINO APPLICATION INFORMATION SB'l'!ET THIS SHEET PROVIDES GDn:RAL INFORMATION CONCERNING THE CONTACTS, COIL AND OPEJlATINO CRA.RACTERISTICS FOR THIS Rl!:LAr. TYPE OF RELAY. PD-1 flasher Staged tteutral W/Heavy Duty Front & RELAY PART NUMBER. 99275037 QTY. AND TYPE OF CONTACTS: DRAWING NUMBER~ f&B, (Sllver to Stlverl ~ 1.rJ. WIRE SIZE, RELAY COIL RESISTANCE. 125 OHMS, (X] Back REAR SERVICE 6 1 700 TURNS. ( J SHELF MOUNT 74655026 PLUG COUPLER PART NO. (J TRAIN CARRIED ( J FRONT SERVICE CONTACT DATA APPLICATION ( J (SJ SAFETY. UP TO JO MAX. RATING VOLTS. MAX. RATING AMPS. 4 (X) (HD) HEAVY DUTY. UP TO JO 10 OPERATING CHARACTERISTICS. NORMAL 12. 0 VDC AMPS CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SIDE 125 Ohm RIGHT SIDE MIN • -1....Q voe AMPS 10 (-)COI~(+)COIL MAX • _J_2Q voe AMPS INTERMITTENT f OPERATING PARAMETERS () HV HIGH VOLTAGE. 9 OPERATING TIME AT !ICK-UP Q....QLSECOND NOR.MAL VOLTAGE (X . AMPS. ( RELEASE 0.04 SECOND FACTORY STANDARD CALIBRATION VALUE 8 7 ) DROP-AWAY .L..Q_ voe AMPS 6 4FIHQI JFCHPJ PICK-UP 1..,_Q_ voe AMPS s llL._ WORKING J..:...Q_ voe AMPS 4 4F8 IHD l 38 IHQ) J 2FIHQ) lP'(ijpl l IN SERVICE APPLICATIO~ICK-UP MAX. l..:.1.Q_ LIMITS. lDROP-AWAY MIN.2..:..§.2 OPERATING TEMPERATURE RANGE. voe 0.264 voe 0.0053 AMPS -40°F to +1SS°F. AMPS 2 l 4ij 2H 2BIHD1 llL__ ll.!lm NOTES 1. 2. J. 4. Thi• relay ahall be tested on a periodic ba•i•, not exceeding 2 year• or currant FRA-required testing interval. When relay operate out side the inaervice application limit• value, it •hall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive load• only, derate 60\ for inductive and 40\ for motor load. When this relay is used with Transcontrol Relay Driver Style (F.R.0.0) Part Numl:ler 75335009, it will provide 43 2 Flaahes per minute, at&rting at 10 voe. z A-24 REI..AY 1!:NOINl!!ERINO APPLICATION INFORMATION SR!:ET TllIS SKEE'r PROVIDES 01!:X!!RJU. INFORMATION CONCERNING TBE CONTACTS, COIL AND OPE:aATIHG CRAJUCTERISTICS FOR TBIS RELAY, TYPE OF RELAY, PO-l Light Out. Biased Neutral tow Volt, COIL INDEX r=1:i DRAWING NUMBER SC517 RELAY PART NUMBER. 99275048 QTY, AND TYPE OF CONTACTS: ii:§. FISilver Carbon to Silver}BISilver to Silver\ A-Coil- ,15 A-Coil 114 A-Coil 180 RELAY COIL RESISTANCE.a-Coil- .:liQ OHMS, a-coil 1.12. WIRE SIZE,B-Coil .i12.Q. TURNS. (XJ REAR SERVICE ( I SHELF MOUNT 7465SOJ7 PLUG COUPLER PART NO, ( l FRONT SERVICE ( l TRAIN CARRIED CONTACT CATA APPLICATION KAX. RATING VOLTS, MAX, RATING AMPS, (S) SAFETY, UP TO 30 4 (XJ CI (HO) HEAVY DUTY, UP TO 30 10 OPERATING CHARACTERISTICS. CONTACTS ARRANGEMENT AS VIEWED F'ROK REAR LEFT SIDE A-Coil RIGHT SIDE A B NORMAL l l . _ VlJC 1...:.j_Q_ AMPS OPERATING PARAMETERS MIN, voe 8.25 0.80 [ l HY HIGH VOLTAQZ, __ry-y""\_ AMPS 10 (-)COIL voe 9 _2_ AMPS INTERMITTENT A OPERATING TIME AT PICK-UP ___._i1 ..:.l2.__SECOND NORMAL VOLTAGE (XJ B A AMPS. (XJ RELEASE~ ..._Q1.i SECOND a-coil A-Coil DROP-AWAY 3.25 voe Q...,2QQ AMPS MAX, _llQ a FACTORY STANDARD CALIBRATION VALUE + S B-Coi~ (+)COIL ,15 Ohm J 350 OM 7 6 4F ~ PICK-UP .L.ll voe Ll.QQ AMPS s 4H 1H.._ WORKING Ll.i voe 0.800 AMPS 4 48 ll voe 0.880 AMPS 3 2F ~ voe o.~01 AMPS 2 rn .lli.._ INSERVICE APPLICATION PICK-UP MAX. 2.....Q.L LIMITS, DROP-AWAY MIN,1.....ll OPERATING TEMPERATURE RANCE. l ~e ll NOTES l. 2, 3. Thi• relay shall ba te1ted on a periodic basia, not exceeding 2 year• or current FRA-required testing interval. When relay operate out side the inservice application limits value, it sh~ll be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is baaed on resistive loads only, derate 60\ for inductive and 40\ for motor load. A-25 R!:LAY ENOIH!:!KINO APPLICATION INl'OJUCA~IOH S ~ THIS SHEET PROVIDES OEN!:RAL INFORMATION CONCERNING TBZ COH'l'AC'l'S, COIL AND OPE~INO CB.ARACTERISTICS FOR THIS RELAY. TYPE OF RELAY. P0-1 Hagnetic Stick, Biased Neutral. RELAY PART NUMBER. 99275070 Low Volt DRAWING NUMBER 5C521 REV-1 QTY. ANO TYPE OF CONTACTS: 4FB f&S {Carbon RELAY COIL RESISTANCE. 3500/220 OHMS, INDEX CODE &=It Silver to silver) 134/31 WIRE SIZE, 35,000/6.750 TURNS. (] REAR SERVICE ( ) SHELF MOUNT () FRONT SERVIC! ~ - - - - (XJ TRAIN CARRIED 74675299 PLUG COUPLER PART NO. CONTACT DATA ( XJ APPLICATION HJUC. RATING VOLTS. ( S ) SAFETY. () UP TO 30 MAX. RATING AMPS. 4 ro= (HD) HEAVY DUTY. UP TO JO 10 OPERATING PARAMETERS HIN. AMPS 15.6/5.75 voe AMPS MAX. (HV) 28 280 voe 10 (-)COIL~(+)COIL 220 Ohm 9 _ _ ( - ~ ( + ) _ __ AMPS INTERMITTENT OPERATING TIME AT!(, icK-UP 0.10 SECOND NORMAL VOLTAGE (X AMPS. ( J RELEASE 2..:..1.Q. SECOND FACTORY STANDARD CALIBRATION VALUE 8 7 ) :~~G 15.8/5.75 voe AMPS REVERSE WORXINC 15.6/5.75 VDe AMPS l HIGH VOLTAGE. CONTACTS AR.RANCE.Ml!!NT AS VIEWED l'ROK REAR LEFT SIDE 3,500 Ohma RIGHT SIDE OPERATING CHARACTERISTICS. voe () IN SERVICE APPLICATIO~ NORMAL LIMITS. <WORKING 17.38/6.32 voe .005/.287 AMPS LWORXINC.17.38/6.32 REVERSE 4P'IS) 6 5 4H 4 4BISJ. 3 lli.ll VDe .005/.0287 AMP OPEl'Ul.TING TEMPERATURE ~GE. 1 ll.Lll NOTES 1. 2. 3. This relay shall be tested on a periodic baai•, not exceeding 2 year• or currant FRA-raq,.iirad testing interval. When relay operate out side the inae.rvice application limit• value, it shall be reconditioned as per P0-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating i• baaed on resistive load• only, derate 60\ for inductive and 40\ for motor load. A-26 RELAY ENGINEERING APPLICATION INFORMATION SHEET THIS SHEET PROVIDES GENERAL INFORMATION CONCERNING THE CONTACTS, COIL ANO OPERATING CHARACTERISTICS FOR THIS RELAY. TYPe: oF RELAY. PD-1 Magnetic Stick, Biased. Neutral, Low Volt RELAY PART NUMBER. 99275180 4N-4R QTY. ANO TYPE OF CONTACTS: RELAY COIL RESISTANCE. -------125 t.'011. /NOe;t A::£. F&B(Carbon Silver to Silver) OHMS 127 , ,, D 6, 700 WIRE: SIZE, 74655002 !I) . A£M SGMC£ Pt.UG COUPLER PART HO. 5C538 Re'(. C DRAWING WMSER. D SHEi.Ji' TURNS. MC(.tfT' - - - - - - O TR.UC CAARlliD - - - - - F'AOH1' SQMc:11: - - - - - CONT ACT DAT A [1 APPLICATION MAX. RA TING VOLTS. (S) SAFETY. 0 OPERATING CHARACTERISTICS. {: OPERATING TIME AT NORMAL VOLTAGE:. AMPS, 8 FACTORY STANOARO CALIBRATION VALUE. {= r=l LEFT SIOC 12s.n. RIGHT SU 10 ( · ) C O l ~ • ) C O I L AM'S IHT£RMITT£HT. g --- - 0.10 S&COtO a --·-- 0 • 10 S£c:ac> ...7 Reverse MAX. OlltCl'-AWAY MIN. OPERATING TEMPERA TUR£ RANGE. AS VIEWED FROM REAR /.MPS AM"S w~i:kfng {PIOC~ CONTACTS ARRANGEMENT 12.0 lt'OC 5.0 v oc 120 v oc WOAKIHG JNSERVICE APPICA TION LIMITS. (HV) HIGH VOLTAGE. 10 4 OPERATING PARAMETERS 0 UP TO 30 UP TO 30 MAX. RATING AMPS. (HO) HEAVY DUTY. 5.0 Y. DC N4'S JE.C~ .1fi_ _!t!!J~ l~..C~ 3H --.-- s.o Y. DC ~ 4 5.so Y.DC~ .3 5.so v. oe 0.044 • -40 F TO •18!5• F. N..-s --- -.. e JE.C~ !5 . ---- ------- 2 2H ---2B (S) ---- -~£SJ -11:.1~ -1B1H--(S) --- - NOTES I. 2. 3. THIS .RELAY SHALL Be: TESTED ON A PERIODIC BASIS, NOT EXCEEDING 2 YEARS OR CURRENT FRA·REOUIRED TESTING IHTER\lAL. WHEN RELAY OPERATE OVT SIDE THE INSERVICE APPLICATION LIMITS VAWEt IT SHALL BE RECONDITIONED AS PER PO-I RELAY SHOPPING PROCEDURE ANO CAUBR,\TE TO FACTORY S ANOARO CALIBRATlOH VALUE. CONTACT AMPERE RATING IS BASED ON RESISTIVE LOADS ONLY, DERATE 60 % FOR INDUCTIVE ANO 40% FOR MOTOR LOAD. A-27 ULAX' ENOIN?:!:JlIHO APPLICATION IHP'ORXATIOH SU:!:'1' THIS SH!:!:'l' PROVIDES OEHERJU. IH!'ORMATIOH COHC!:R.HIHO THE CON'rACTS, COIL AND OPEJlATIHO CRARACT!:RISTICS !'OR THIS RELAY, TYPE oF RELAY. PQ-1 Power off, BLaeed Neutral RELAY PART NUMBER. 99275257 DRAWING NUMBER~ 1lJl F&B(Carbon Silver to Silver) B HD (Silver to Silver) QTY. AND TYPE OF CONTACTS: _..,.1_2....5__ RELAY COIL RESISTANCE. (XJ OHMS, 121 REAR SERVICE 74655048 L..1.QQ. TURNS. WIRE SIZE, [] SHELi' MOUNT PLUG COUPLER PART NO. ( ) FRONT SERVICE------ [] TRAIN CARRIED 74675299 CONTACT DATA APPLICATION MAX. RATING VOLTS, MAX. RATING AMPS. [X) [X] ( S ) SAFETY, UP TO 30 4 (HD) HEAVY DUTY. UP TO 30 10 AMPS CONTACTS ARRANOZHZHT AS VIEWED FROM R!:AR LEFT SIDE 125 Ohm RIGHT SIDE AMPS 10 (-)COI~+)COIL OPERATING CHARACTERISTICS. I::~ I::: :: OPERATING PARAMETERS KAX. AMPS INTERMITTENT _llQ_ voe OPERATING TIME AT ~PICK-UP NORMAL VOLTAGE (X AMPS. ( RELEASE 0.07 0.04 [) (HV) HIGH VOLTAOZ. SECOND 9 8 SECOND 7 CROP-AWA:! .....L.Q. voe AMPS 6 .il.Lll PICK-UP .i..Q voe AMPS 5 ilL. WORKING .L.Q. voe AMPS 4 48rH.p.l 3BCH, P, I INSERVICE APPLICATI01PICK-UP MAX. 1.....1Q LIMITS. fROP-AWAY MIN,0.67 voe ~AMPS 3 lll.ll ll.Lil voe .:..2.Q..i._AMPS 2 l.!i FACTORY STANDARD CALIBRATION VALUE i OPERATING TEMPERATURE RANCE. -40°F to +185°F. 1 llW:l,Q,l 3P'CSJ -1JL -1.L Ul!tl,Q, l NOTES 1. 2. J, 4. 5. This relay shall be tested on a periodic basis, not exceeding 2 year• or current FRA-required tasting interval. When relay operate out side the inaervice application limit• value, it shall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating ia based on resistive loads only, darate 60\ for inductive and 40\ for motor load. When P.O. Rectifier unit Part no. 78805088 ia in circuit, min. drop-away value is 6.70V.AC. and max. pick-up, work at 9.0V.AC. When this relay is used for other application, plug coupler P/N 74655002 •hall be U88d, A-28 IU!:LAY !HOINEERIHO APPLICATION INFORMATION SHEET THIS SHEET PROVIDES OENJ:JU.L INFORMATION CONC!RNINO THE CONTACTS, COIL AND OPSJlA~IHG C!!AJtACTERISTICS FOR Tl!IS IU!:LAY. TYPE OF RELAY. PD-1 Magnetic Stick Low Volt RELAY PART NUMBER. 99275334 DRAWING NUMBER 5C573 QTY. ANO TYPE OF CONTACTS: ilL...iR _ .s. . o . . ....o__ RELAY COIL RESISTANCE. REV.-e COO! INDEX~ f&BICarbon Silver to Silveri oHMs, #30 WIRE SIZE, 13,000 TURNS. (X] REAR SERVICE 74655002CK () SHELF MOUNT ( J FRONT SERVICE (] TRAIN CARRIED PLUG COUPLER PART NO. CONTACT CATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS. ( J (HO) HEAVY DUTY. UP TO 30 10 [ X) ( S ) SAFETY. UP TO 30 4 OPERATING CHARACTERISTICS. )::~: OPERATING PARAMETERS ( MAX. voe AMPS CONTACTS A.R.RANG!M!NT AS VIEWED FROM IU!:AR LEFT SIDE 500 Ohm RIGHT SIDE voe AMPS 10 (-)COIG+)COIL 2K,2W 11.Q_ voe AMPS INTERMITTENT co~ 9__ 7 WORKING lQ...Q voe AMPS 6 ~ REVERSE WORKING ~ voe AMPS 5 .itL.. IN SERVICE APPLICATIO~PICK-UP KAX. 1.L.Q LIMITS. ROP-AWAY MIN.ll.0 OPERATING TEMPERATURE RANGE. -- a OPERATING TIME AT ~PICK-UP 0.10 SECOND NORMAL VOLTAGE (X AMPS. ( RELEASE O.10 SECOND FACTORY STANDARD CALIBRATION VALUE () (KV) HIGH VOLTAGE. 3l ! :Z 1 ..l1L 4 4B<Sl JBCSl voe 0.022 AMPS J ll.W ll1ll voe 0.022 AMPS 2 lH -40°F to +1SS°F. 1 n1s1 _lJL Ul(Sl NOTES 1. 2. J. 4. 5. 6. This relay shall be tested on a periodic basis, not exceeding 2 yeara or currant FRA-required testing interval. When relay operate out side the inservica application limit• value, it shall be reconditioned aa per P0-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive loads only, derat• 60\ for inductive and 40\ for motor load. All capacitors are baaed on 500 ohm coil, 2X resistor ia connected in parallel to coil. F- NORMAL B-REVERSE A-29 ,J R.!!LAY ENOIN!!ZRIHO APPLICATION IHFORXATIOH SREr.? TllIS sazrr PROVIDES QZN!!RAL IHFOR.MATIOH CONCERNIHO THE COHTAC':t'S, COIL AND OPEJUI.TIHQ CH.1JU.CTZRISTICS FOR THIS R.l!:LAY. TYPE OF RELAY. P0-1 Overload R.l!:LAY PART NUMBER. 99275607 DRAWING NUMBER lH-lB. lHFB Make QTY. A.NO TYPE OF CONTACTS: SC640 REV-C Before Break. RELAY COIL RESISTANCE. 25/200 OVERLOAD/STICK [XJ REA.R SERVICE 74655101 PLUG COUPLER PA.RT NO. ( ] FRONT SERVICE~~~~~ CONTACT DATA APPLICATION MAX. RATING VOLTS. MAX. RATING AMPS. INDEX F ro= (XJ UP TO JO 10 4 voe AMPS MIN. llill ..11.L voe AMPS MAX. 1,on~o voe <Ptlladiµm-Sllyer Non-Yltall (] TRAIN CARRIED 150 WATT (JA MAX.) CONTACTS ARRANGEMENT AS VIEWED !'ROM REAR LEFT SID! RIGHT SIDE OPERATING CHARACTERISTICS. WITHOUT 0.046 OHM RES. OPERATING PARAMETERS a [J SHELF MOUNT (J (HD) HEAVY DUTY. ( J ( S ) SAFETY. UP TO JO & ~ AMPS INTERMITTENT 9~~O J ,,r OPERATING TIME AT r-10 SEC. NORMAL VOLTAGE ( ) AT AMPS. (XJ 12 AMPS rROP-AWAY FACTORY STANDARD CALIBRATION VALUE WITH 0.046 OHM RESISTOR 0.110., voe AMPS 8 - 7 + Ill N Q 6 _ll 500 Ohm Ra•. ....ll PICK-UP 3/8 voe AMPS 5 WORKING 3/8 voe AMPS 4 INSERVICE APPLICATI~ PICK-UP MAX. 3.3/8.8 voe .132/.044 AMPS 3 LIMITS. tROP-AWAY MIN •. 067(.134 VDC.OOZ/.0007 AMPS 2 1 __ OPERATING TEMPERATURE RANCE. MOTES 1. 2. 3. 4. Thi• relay shall ba teated on a periodic basia, not exceeding 2 year• or current FRA-required testing interval. When relay operate out side the inservica application limit• value, it ahall be reconditioned as per PD-1 relay shopping procedure and calibrate to factor standard calibration value. Contact ampere rating is based on resistive load• only, derate 60\ for inductive and 40\ for motor load. *lF contact is internally wired and this tab i• not brought out on the plug coupler. J A-30 RELAY EHOINZERIHO APPLICATION IHFORXATION SB!!ET THIS SHEET PROVIDES ODl!:RAL INFORMATION COHCERNIHO THE CON'l:AC'l:S, COIL CB.ARACTERISTICS FOR THIS R!:LAY, TYPE OF RELAY. PD-1 RELAY PART NUMBER. Light Oyt AH1) OPEKATIXO Biased Neutral Low Voltage 99275838 DRAWING NUMBER SC642 Rey, 8 COIL INDEX~ QTY, ANO TYPE OF CONTACTS:~ FISilver Carbon to Silver) 8 (Silver to Silveri A-Coil ....ll A-Coil l l i A-Coil .il.Q. RELAY COIL RESISTANCE,B-Coil ~ OHMS, B-Coil ll.i_ WIRE SIZE, a-coil .l.5.Q TUJUIS. (X) REAR SERVICE 74655134 CI SHELi' MOUNT PLUG COUPLER PART NO, ( ( l TRAIN CARRIED l FRONT SERVICE CONTACT CATA APPLICATION RATING VOLTS, MAX. RATING AMPS, (X) 1'{JU(. (S) SAFETY, UP TO JO 4 OPERATING CHARACTERISTICS, OPERATING PARAMETERS ( l (HD) HEAVY DUTY, Coils A & 8 In Serie• OPERATING TIME AT ~PICK-UP NORMAL VOLTAGE ( AMPS. (X] RELEASE voe 1..:..2_ AMPS INTERMITTENT 0.24 HICH VOLTACZ, 9 a a-coll SECOND Ohm• - 0.2 rROP-AWAY PICK-UP FACTORY STANDARD CALIBRATION VALUE WORKING GRADUAL INCREASE & DECREASE OF INPUT CC VOLTAGE INSERVICE APPLICATIO~PICX-UP MAX, LIMITS. ROP-AWA'.i KIN, OPERATING TEMPERATURE RANGE, (HV) CONTACTS A.RRANGEMENT AS VIEWED FROM REAR LEFT SIDE A-Coil RIGHT SIDE 0.37 oruu 10 (-)COI!!_.~+)COIL F~ ---:: ~ ::: MAX, CI UP TO 30 10 SECOND 7 voe ..r.l.2..Q. AMPS 6 voe ~ AMPS 5 .4.H_ lfL voe ~ AMPS 4 41;1 a_ voe ....U.0.....AMPS 3 l.l..Lll voe .:..1.QSLAMPS 2 1l:f._ -40°F to + 1SS°F. 1 4P'<S> ttLll 2a 1.l.il.l. l.tL_ ll._ NOTES l, This relay shall be teated on a periodic baaia, not exceeding 2 year• or current FRA-required testing interval. 2, When relay operate out aide the in1ervice application limit• value, it 1hall J, be reconditioned a• per PD-1 relay shopping procedure and calibrate to factor standard calibration value. See application circuit for light-out. J A-31 lt!!LAY ENOIK'!!!!RIHO APPLICATION IHFOR.MATIOW SBEZ'r THIS SK!!ET PROVID!!S O!!H!!RAL INFORMATION COHCEJUIINO TB!! CONTACTS, COIL ANl> OPEJtATIHO CRAJU.CT!!RISTICS FOR THIS R.l!!LAY. TYPE OF RELAY. PQ-1 Magnetic Blow-Out Biased Neutral RELAY PA.RT NUMBER. 99275860 DRAWING NUMBER l.t:l.a QTY. ANO TYPE OF CONTACTS! 5C655 Rey-0 INDEX CODE B::§. r,scsilyer Graphite to s11yer1 CHY> RELAY COIL RESISTANCE. _.,.,s.,.,o.,.,o__ oHMs, (XJ REAR SERVICE WIRE SIZE, 130 7465511286 13,000 TURNS. ( ) SHELi' MOUNT PLUG COUPLER PART NO. [ J TRAIN CARRIED ( J FRONT SERVICE-------CONTACT CATA ( ) ( S l SAFETY. APPLICATION [XJ (HO) HEAVY DUTY. UP TO 30 15 MAX. RATING VOLTS. MAX. RATING AMPS. OPERATING CHARACTERISTICS. AMPS l::~ :'.~: :: OPERATING PARAMETERS MAX. OPERATING TIME AT !ICK-UP NORMAL VOLTAGE (X AMPS. ( RELEASE l FACTORY STANDARD CALIBRATION VALUE AMPS AMPS INTERMITTENT voe 120 [X) (HV) HIGH VOLTAGE. UP TO lJOV 25 (NOTE 3) CONTACTS ARRANGEMENT AS VIEWED FROM REAR LEFT SID!! 500 Ohm RIGHT SIC! 0, 16 SECOND O,OJ SECOND 7 DROP-AWAY 1.,_Q.Q VDC AMPS 6 ll.W. PICK-UP 1..:..QQ VDC AMPS 5 iH.._ .lli.. WORKING 1.c.9.Q voe AMPS 4 INSERVICE APPLICATION~PICX-UP MAX. 7,70 4BtHY-S) voe o.ois AMPS 3 2[(H:J!-Sl VDC 0.002 AMPS 2 JBtH. P, 1 LIMITS. ROP-AWAY KIN.l....ll OPERATING TEMPERATURE RANGE. -40°F to +lSS°F. 2H :!: l lll!Hd~·l NO't!!S l. 2. 3. 4. This relay shall be tested on a periodic basis, not exceeding 2 years or currant FRA-requirad tasting interval. When relay operate out side the inservica application limit• value, it shall be reconditioned•• per PD-l relay shopping procedure and calibrate to factor standard calibration value. In connection with arc quenching magnet, intermittant duty. Applications Switch machine llOV DC load control. ./ A-32 RZI.Ar ENGINZEKING APPLICATION INFORMATION SBEr.l: TKIS SBEE'r PROVIDES OEHZJlAL INFORHATIOK CONCERNING TBB COK'l'ACTS, COIL AND OPERATINO CJIAJtACT!!RISTICS FOR TllIS RELAY. TYPE or RELAY. po-1 slow Relea11 Bta,ad Neutral tow Voltage. RELAY PART NUMBER. 99275882 DRAWINC NUMBER 5C557 REV-b INDEX .a::.2, J ~Tr. ANO TYPE OF CONTACTS: i.tii F{Carbon Silyer to Silyerl 8/Silyer to Sily•r) i l l WIRE SIZE, RELAX' COIL RESISTANCE. 1QSL OHMS, (X] REAR SERVICE 6,500 TURNS. ( l SHli:LJ' MOUNT H!z55QQ2 PLUG COUPLER PART NO. APPLICATION RAT INC VOLTS. RAT INC AMPS. ( I TRAIN CARRIED I FRONT SERVICE ( CONTACT CATA (X) MAX. MAX. CI (HD) HEAVY DUTY. (S) SAFETY. UP TO 30 4 (l OPERATINC CHARACTERISTICS. t= OPERATINC PARAMETERS MIN. I MAX. OPERATING TIME AT NORMAL VOLTACE ( ic I AMPS. ( l FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. HICK VOLTACIC. CONTACTS ARRANCEK!NT AS VIEWED FROM REAR LEFT SIDE 200 Ohm RICHT SIDI .ll....Q voe AMPS ~ voe AMPS li.Q voe AMPS INTERMITTENT 10 9 (-)COI~+)COIL 6P' IS) SF 1s1 1JC,2W PICX-UP Q...ll SECOND RELEASE 2.:...2_ SECOND at 12V J (HV) UP TO 30 10 8 6fj SH - 7. 68 SB DROP-AWA? -1.....Q voe AMPS 6 4F 1s1 3F IS l PICK-UP --2..L.i voe AMPS 5 41:f 3H WORKING -9...:..i voe AMPS 4 48 38 rPICX-UP MAX. -1.,J..!. voe 0.0~6 AMPS 3 a CROP-AWAY MIN.!...,.ll voe 0.067 AMPS 2 2H OPERATINC TEMPERATURE RANCE. -40°F to +185°F. 1 a Is 2 lF ISi lH u NOT!!S 1. 2. 3. 4. 5. This relay shall be tasted on a periodic basis, not exceeding 2 year• or currant FRA-required testing interval. When relay operate out aid• the inaervice application limits value, it shall be rec~nditioned as per P0-1 relay shopping procedure and calibrate to !actor standard calibration value. Contact a.rnpere rating is based on resistive loads only, derate so, for inductive an~ 40\ for motor load. All calculations are based on 200 ohm coil. lK reaistor is connected in parallel to coil. J A-33 RELAY EHOIN!'!ERINQ APPLICATION INFORMA~IOH SJIEE"r TBIS SBEZT PROVIDES OEMZKAl. INFOJUCATIOH CONCEJUfINO TBE COHTAC'l'S, COIL AND OPBJtATINO C!l.AltACT!!RISTICS roR THIS RELAY. TYPE OF RELAY. P0-1 Ord. Acting Biased Neutral Low RELAY PART NUMBER. 99275893 QTY. ANO TYPE OF CONTACTS: Voltage, DRAWING NUMBER 5C658 REV-A ~ INDEX~ [(Carbon Silver to Silver) BISLlyer to Slly•r) t1!l WIRE SI Zl!! I R!!LAY COIL RESISTAHCZ. l.Q.SL OHMS, [X) REAR SERVICE 13,000 TtlR.NS. I I SHELF MOUNT 74655QQ2 PLUG COUPLER PART NO. ( I TRAIN CARRIED I FRONT SERVICE [ CONTACT DATA APPLICATION MAX. RATING VOLT:S. HAX. RATING AHPS. [ I (HD) HEAVY DUTY. [X] (S) SAFETY. UP TO 30 [1 (HV) HIGH VOLTAGZ. UP TO 30 10 4 OPERATING CHARACTERISTICS. CONTACTS ARRANGEMENT AS VIEWZD FROH REAR LEFT SID! 500 Ohm RIGHT SIOI ll.r..Q voe AMPS ...9..:..i voe AMPS .ll2. voe AMPS INTERMITTENT rO-L OPERATING PARAMETERS MIN. ! MAX. OPERATING TIME AT NORMAL VOLTAGE [X) AHPS. ( I FACTORY STANDARD CALIBRATION VALUE INSERVICE APPLICATION LIMITS. PICK-UP 10 (-)COI~L cs l 9 61! SECOND a 6H 5!:I SECOND at 12V 7' 68 58 2lC,2W ll...l.:i RELEASE Q.Jll } DROP-AWAX -l....2 VDC AMPS 6 4P' (S) 3P' PICK-UP ___L.;. VDC AMPS s 4H 3H WORXING --6..r.i VDC AMPS 4 48 38 ! VDC .QUJ AMPS 3 u DROP-AWAI MIN.L,ll voe .QQU AMPS 2 2H PICK-UP MAX • OPERATING TEMPERATURE RANGE. ..L.ll -40°F to +185°P'. 1 a (Sl lP' ($) (S\ lH 18 HOT!!S 1. 2. J. 4. 5. This relay ahall be tested on a periodic basia, not exceeding 2 yeara or current FRA-required teating interval. When relay operate out aide the inaervice application limit• value, it shall be reconditioned &a per P0-1 relay shopping procedure and calibrate to factor st~ndard calibration value. Contact ampere rating ia baaed on raaistive load• only, derate 60\ for inductive and 40\ for motor load. All calculation• are baaed on 500 Ohm coil, 2K r••i•tor is connected in parallel to coil. I A-34