AF-500 TUNED MINIBOND - Global Product Support · SERVICE MANUAL 6352 Description, Operation & Maintenance AF-500 TUNED MINIBOND July, 1985 (Rev. 7/87) ID0048F/DN0017F B-7/87-40-2781-1

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SERVICE MANUAL 6352

Description, Operation & Maintenance

AF-500 TUNED MINIBOND

July, 1985 (Rev. 7/87) ID0048F/DN0017F B-7/87-40-2781-1

Part Numbers

N451486-0701

N451486-0702

UNION SWITCH & SIGNAL AMERICAN STANDARD INC • PO BOX 420 • PGH.; .PA 15;/30

PRINTED IN USA

m UNION SWITCH & SIGNAL

A

REVISION INDEX

Revised pages of this manual are listed below by page number and date of revision.

Page Number

2 3 5

7/8 12 13 25 35 A-1 A-2 A-5/6 A-7/8 A-15

Date of Revision

6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87 6/87

Section

1.1 1.2 1.3 1. 3.1 1.3.2

II.

2.1 2.1.1 2.1.2 2 .1. 3

2.2 2.2.1 2.2.2

III.

3.1 3.2 3. 2.1· 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

IV.

4.1 4.2 4.2.1 4.2.2 4.2.3

INTRODUCTION DESCRIPTION SPECIFICATIONS Electrical Mechanical

INSTALLATION

GENERAL

CONTENTS

Track Preparations Installation of Cables Cable Connections APPLICATION Selecting Frequency Group Installation

FUNCTIONAL DESCRIPTION

BASIC CONCEPTS DESIGN CONCEPTS General Bond Impedance Across the Track Terminals High "Q" Parallel Resonant Circuit Series Connected High "Q" Parallel Resonant Circuit Minibond Impedance Versus Frequency Analysis Conclusions and Comments

MAINTENANCE

FIELD INSPECTION AND MAINTENANCE SHOP MAINTENANCE Troubleshooting Tuning Bond Assembly

APPENDIX - A PARTS LIST

i

UNION SWITCH & SIGNAL m

1 1 2 2 2

5

5 5 5 5 6 6 6

9

9 12 12 12 15 15 15 19

21

21 21 21 25 34

~ UN.ION SWITCH & SIGNAL

Figure

2-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8

A-1 A-2 A-3 A-4 A-5 A-6 A-7

LIST OF ILLUSTRATIONS

Typical Installation - Wood Ties AF-Mini Impedance Bond - Basic Circuit Typical Propulsion Current Flow AF-Mini Impedance Bond - Circuit Application Tuned Minibond Schematic Equivalent Circuit of Figure 3-4 Parallel Resonant Circuit Impedance Versus Frequency Reactive Impedance Versus Frequency Impedance Versus Frequency Three Circuits in Series Circuit View From One Resonant Circuit Impedance Reflected to Cable Terminals Basic Tuning Circuit Adding Capacitance Three Parallel Resonant Circuits Actual Tuning Configuration Cab Transmitter Tuning Wiring Diagram for Table 4-2 Tuned Minibond Wiring Diagram Wiring Diagram for Table 4-5

Minibond Assembly Coupling Unit Assembly Track Transmitter & Receiver PCB Cab Transmitter PCB Track Transmitter & Receiver ~iring Diagram Cab Transmitter Wiring Diagram Connecting Cable

ii

7 9

10 11 13 14 16 17 17 18 18 20 25 26 26 27 28 30 35 37

A-3/4 A-7/8 A-10 A-12 A-13 A-13 A-15

1.1 INTRODUCTION

SECTION I GENERAL INFORMATION

UNION SWITCH & SIGNAL ffi

The Tuned Minibond is an extension of the basic audio frequency (AF) minibond with a center tapped primary and an inductively coupled secondary winding that is tuned to increase the impedance of the bond at desired frequencies.

1.2 DESCRIPTION

Like the basic AF Minibonds, the AF-500 Tuned Minibonds have a center-tapped propulsion winding and permit coupling of ac signals between the secondary winding and the propulsion winding. The AF-500 minibond differs in the number of cores and the tapped secondary windings. The bond contains four coils. Two of the four coils within the bond are connected in parallel, hence the bond will effectively have three magnetic cores. The propulsion winding is common to all three cores.

The high turn terminals of the secondary winding of one core is tuned to the cab signaling frequency of 4550 Hz. The remaining windings (track receiver and track transmitter) are tuned to each of the eight train detection frequencies. This is achieved by inserting additional capacitance into the tuned circuits by connesting or disconnecting a jumper strap(s). This arrangement allows the customer to choose the frequency group for the bond. The single part number eases purchasing and inventory.

The tapped secondary windings function as an auto-transformer. The tap lead and the auto-transformer common leads of the three windings are series connected and connected in parallel with the high side of a coupling transformer. The transformer's low side is connected to the wayside cable.

Each tuned circuit is a parallel resonant circuit. Since each circuit has its own magnetic core, the bond impedance can be represented as the sum of the reflected complex impedances of the resonant circuits. This is true for both the propulsion winding termination and the wayside termination. Section 3.2 (Design Concepts) discusses this in more detail.

Each circuit is tuned to a different (typically) frequency called the resonant frequency. The jumper straps allow one choice of eight frequencies for both the train detection transmitter coil and train detection receiver coil. It is possible to choose the same frequency for both. There is little reason to do so. The cab has only one frequency available, 4550 Hz.

At the resonant frequency the impedance of the resonant circuit is high. The reflected impedance to the track or wayside will also be high. In summary, the tuned minibond's reflected impedance to the track or wayside terminals will be high near any one of the three resonant frequencies. Away from the resonant frequencies, the bond impedance will be low.

6352, p, l


1.3 SPECIFICATIONS

1.3.1 Electrical

Style: Type: D.c. Resistance: Current Unbalance:

D.c. Propulsion current:

AF-Mini o.c. Propulsion 0.00003 ohms+ 10% rail-to-rail at 2ooc 240 amps de through one turn of the propulsion winding, based upon the operating characteristics of the AF-500 track circuit system. 3000 amperes de continuous per rail

Frequency Groups and Impedances (Z)

Cab Transmitter Track Transmitter Track Receiver Freq. (Hz) z (Ohms) Freq. (Hz) z (Ohms) Freq. (Hz) z (Ohms)

4550, 1.15 1900, .361 3370, 1. 76 4550, 1.15 2100, .433 3100, 1.62 4550, 1.15 2580, .611 3900, 1.97 4550, 1.15 2820, • 730 3660, 1.88 4550, 1.15 3100, .887 2580, 1.28 4550, 1.15 3370, 1.01 2820, 1.42 4550, 1.15 3660, 1.08 1900, .<}42 4550, 1.15 3900, 1.20 2100, 1.05

Bond measured with 0.1 MFD load at wayside terminals. Values are measured at 2ooc, 0 amps de unbalance current at specific voltage levels. Impedance tolerance is+ 15% (rail-to-rail). Frequency tuning tolerance is+ 5 Hz across tuned circuit of interest. More specific information is listed in Section 4.2.2 (Tuning).

1.3.2 Mechanical

1.3.2.1 Two Piece .Design

The AF-500 Tuned Minibond, as shown in the chart below, is composed of two units; a minibond and a coupling unit. Typically, the two units are mounted between the rails on wooden ties as shown in Figure 2-1. The two units are electrically connected with a seven-conductor umbilical cable. A cable-grip is provided on t~e coupling unit for a cable to connect the Coupling Unit to the wayside signaling equipment. Figures A-1 and A-2 illustrate these units. A typical installation is given in Section II.

6352, p. 2

Tuned Minibond

N451486-0701 N451486-0702

Minibond

N451003-1101 N451003-1102

coupling Unit

N451003-1201 N451003-1202

(Rev. 6/87)

UNION SWITCH & SIGNAL

Tuned Minibond N451486-0702 is an improved version of N451486-0701. Coil turns ratio of the minibond component were changed to increase the power delivered to the track circuit. The coupling units, N451003-1201 and -1202 are both physically and electrically identical, the difference being that N451003-1202 contains a schematic for Tuned Minibond N451486-0702 instead of N451486-0701. Both N451486-0701 and N451003-1101 have been obsoleted. Part numbers N451486-0702 and N451003-1102 respectively can be substituted for them. substitution of minibond components may require a tuning adjustment. Coupling unit N451004-1201 can be updated to a -1202 by simply affixing a new schematic diagram to it.

a. Minibond Unit

The AF-500 Minibond utilizes moly-permalloy toroidal cores to construct four coils. For Minibond N451003-1101, three of the coils are tapped and the remaining coil is placed in parallel with the third tapped coil. For Minibond N451003-1102, two coils are tapped; the other two coils are in parallel with no taps. The coils are bound together to form a coil assembly. The taps divide each coil winding into two sections. The "high turns" sections are series connected with adding polarities. The tap lead of the first coil and the start and finish lead of all three coils (7 leads total) are soldered to connector pins. The above, and a fabricated sheet-metal housing are assembled into a mold. The mold is filled with an epoxy compound and is cured under appropriate conditions.

b. coupling Unit

The outer shell of the coupling Unit is a fabricated sheet-metal box. Two mounting flanges are welded to the box. A hinged door is located on the top of the box. A wiring diagram is located on the inside of the door. The box has four hold-down clamps and provides for use of a padlock. The box contains two cable-grips. The larger cable grip holds the sevenconductor umbilical cable which connects the Coupling Unit to the Minibond. The other cable-grip is provided for the cable from the wayside equipment.

Within the outer shell is another fabricated sheet-metal box. This box is shock-mounted. rt contains three printed circuit boards. The boards contain the capacitors and resistors needed to tune the Minibond. One board also contains a transformer which couples the signals between the Tuned Minibond and wayside equipment. "U-channel" slots and a micarta retaining plate hold the printed circuit boards in place. The electrical connections between the cables and printed circuit boards are made with "Fast-on terminals".

Appropriate use of jumper straps, located on the printed circuit board, allows the customer to choose which frequencies the bond will operate at.

The printed circuit boards are not part of the coupling Unit's bill of material. They are listed in the bill of materials of the Tuned Minibond.

(Rev. 6/87) 6352, p. 3


1.3.2.2 •Married Pairs•

A Minibond, a Coupling Unit, and a set of printed circuit boards are tested, adjusted, and assembled into the final product; a Tuned Minibond. Fine tuning capacitors and impedance adjusting resistors are selected during factory test and placed in the appropriate circuits. This is required due to the tolerances associated with the minibond coils. The resulting Minibond and the Coupling Unit are considered to be one functional unit and are referred to as a •married pair•.

Each unit of the married pair bears two serial numbers on its nameplate. One serial number pertains to the individual unit, Minibond or Coupling Unit. The second serial number pertains to the married pair, and will appear on the nameplate of both units. Individual replacement units supplied to customers (who do their own fine tuning and impedance adjustments) will have "NA" (not applicable) stamped on the nameplate in place of the serial number of the married pair. •Mixed" Minibonds and coupling Units may or may not be functional for all operating conditions.

1.3.2.3 Weight

N451003-1101 Minibond Component N451003-1201 Coupling Component Total weight

6352, p. 4

58-1/2 Lbs. 20 Lbs.

78-1/2 Lbs.

2.1 GENERAL

SECTION II INSTALLATION

WARNING


TO AVOID PERSONAL INJURY WHILE INSTALLING IMPEDANCE BONDS, BE SURE TO DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA.

NOTE

Installation requirements for an impedance bond are controlled primarily by the physical specifications of the user's trackage and associated signal hardware. The following remarks and drawings are intended only as a general guide to installation. The customer should make whatever adjustments are necessary to insure (a) that the bonds, cables and other pieces are well secured, with no possibility of being damaged by low hanging vehicle rigging, wheel flanges, etc. and (b) the section of track outfitted with the bonds maintains standards for tie spacing, ballast support, etc.

2.1.1 Track Preparations

Using the appropriate installation drawing for the impedance bond, reposition and refashion the ties as needed to meet basic mounting requirements for the unit and any auxiliary pieces such as a protective ramp. Replace any deteriorated ties which may not hold attachment screw threads reliably. Where necessary, excavate ballast between the ties to insure that the bond will rest flush against the ties. Use the application drawing to locate hold-down screw holes for the bond and other pieces, with the object of installing the equipment on the center line between the rails.

2.1.2 Installation of Cables

Bond-to-bond cables are prepared according to the basic distance between bond units · and special requirements such as crossbonding to other tracks. Propulsion cables should be prepared with length sufficient to take up rail running motion. Have the ties support the cable as much as possible and secure the cable to the tie so that only the outward end absorbs rail movements.

2.1.3 Cable Connections

I A tin foil gasket (M056961) has been used between cable lugs and impedance bond terminals. This gasket improves conductivity by filling imperfections in the mating surfaces. The same result is achieved by tinning the terminals and lugs.

(Rev. 6/87) 6352, p. 5


a. When a tinned or smooth surface lug is used with an impedance bond having tinned terminals, the tin foil gasket may be omitted.

b. A tin foil gasket shall be used between the mating surfaces of an impedance bond terminal and cast cable lug or where the mating surfaces are not smooth.

Corrosion at the bond terminal connections can be reduced by coating the connecting surfaces with a corrosion preventive type of oil or grease. A conductive type is recommended.

2.2 APPLICATION

2.2.1 Selecting Frequency Group

2.2.2

It is more convenient to select the frequency group to be used prior to installation. For new units this requires opening the coupling Unit and cutting the appropriate buss wire segments (maximum of two). The segments chosen should be severed at both ends of the segment. Do not let a segment fall into the Coupling Unit. A wiring diagram posted on the inside of the door illustrates which buss wire segments to cut to obtain the desired frequencies. These are also shown in Figure A-5.

Required tools are a straight edge screwdriver and a small pair of wire cutters (i.e., diagonal). A soldering iron, solder, #18 buss wire and electrical soldering flux will be required to replace segments.

Installation

Crimp "Fast-on" terminals to wayside cable leads.

Install the Minibond and Coupling Unit components on the track using Figure 2-1 as a guide. Tie spacing should be adjusted to the range indicated. Feed the wayside cable through the cable grip and attach the leads per the wiring diagram. Tighten the cable grip. Close and fasten the lid.

connect the umbilical cable connector to the Minibond component.

Attach propulsion (rail and ground) cables to the Minibond component.

A padlock can be placed on the Coupling Unit component.

Required tools are a straight edge screwdriver (to open lid), 3/4 inch open end wrench or square head socket (tighten lag screws). Crimp tool for "fast-on" terminals, two 1-1/8 inch open end wrenches or one open end and one hex head socket, center tap, and a drill with appropriate drill bit to form guide holes for the lag screws.

Additional tools may be required to attach propulsion cables and adjust tie spacing. A padlock key will be required for removal of the Coupling Unit component since the wayside cable connection is internal to the Coupling Unit.

6352, p. 6

£ TRACK


n,-- nn =1 ____ ___.__1 _ _ __ _ _ _ _u __ ,_______, .,

I --:--!---"'

-- -- --£?f -_- - . \olAYSIO( 1rr,/ I JROUNO CABl: l I : : I C.Al!oLE

,.. , I JO ",

~Mlll(R•:)I II !'\AX (REF)

101'\IM(REF)

ti MAX(REF)

(RU.)(4) i1N. LAG SOLTS

I I I I

I 1 --1

I I

Figure 2-1. Typical Installation - wood Ties

(Rev. 6/87) 6352, p. 7/8

3.1 BASIC CONCEPTS

SECTION III FUNCTIONAL DESCRIPTION


The AF-500 tuned minibond design and application is an extension of the basic concept described below. The basic circuit configuration for an audio frequency (AF) minibond is represented by a primary winding with a center tap and a secondary winding inductively coupled to it (see Figure 3-1). The_ secondary winding may be tuned to increase the impedance of the bond at desired frequencies.

The center-tap divides the primary winding into two sections having an equal number of turns. Ideally the de resistance of each section would be the same. The primary winding carries the propulsion current, hence it is constructed with heavy copper.

CENTER TAP

RAIL 1 RAIL 2

(Note: The designations Propulsion (Pl and P2) and Signal (Sl and S2) are for installation reference.)

Figure 3-1. AF-Mini Impedance Bond - Basic Circuit

Typically, propulsion current can flow through the bond in four ways. Other variations exist.

1. Enters from both rails and exits at the center-tap, see Figure 3-2A.

2. Enters from the center-tap and exits at both rails, see Figure 3-28.

3. Enters at one rail and exits at the other rail. Usually, the center-tap would not be used, see Figure 3-2C.

4. Enters at one rail and exits at the ~enter-tap or vice-versa, see Figure 3-2D.

6352, p. 9

83 UNION SWITCH & SIGNAL

RAIL 1

DC CURRENT ..

S1 TOTAL t AC l

PROPULSION Vac SIGNAL CURRENT CURRENT .J

S2

DC CURRENT i#

RAIL 2

Figure 3-2A

RAIL 1

DC CURRENT ll S1 •

AC ----. Vac SIGNAL

CURRENT _, S2

DC CURRENT -RAIL 2

Figure 3-28

RAIL 1

DC CURRENT BALANCING CURRENT .. TOTAL t AC

PROPULSION Vac SIGNAL CURRENT CURRENT

S1

S2

-. _;

RAIL 2

Figure 3-2C

RAIL 1 TOTAL +

PROPULSION ------------•,......, CURRENT ·~

t Vac

AC SIGNAL

CURRENT --"----4 82 ___ __,

RAIL 2

Figure 3-20

TOTAL PROPULSION

CURRENT

DC CURRENT

n -,m ,-z .,. ;;I

:v

........... DC CURRENT

TRANSFORMED AC SIGNAL VOLTAGE

t TRANSFORMED

AC SIGNAL VOLTAGE

TRANSFORMED AC SIGNAL VOLTAGE

t TRANSFORMED

AC SIGNAL VOLTAGE

Figure 3-2. Typical Propulsion Current Flow~----~-~---

6352, p. 10

UNION SWITCH & SIGNAL m For cases 1 and 2, the total de propulsion current flow is divided between the two halves of the primary winding. The current direction in one half will be opposite the current direction of the other half. The magnetic fluxes induced in the magnetic core of the bond will oppose each other and thus will tend to cancel each other. Equal currents (balanced) will cancel completely. An excessively large current unbalance will cause a loss in the ac signaling impedance.

The signaling current (ac) enters through one rail and exits through the other rail. It traverses the whole winding in one direction, hence no ac flux cancellation occurs. An ac signal is induced into the secondary winding. Similarly an ac signal can enter the secondary winding and induce a signal into the primary coil.

For case 3 the bond allows the propulsion currents to be re-distributed. In general, this tends to equalize the current in the rails. In this application, the bond does not benefit from cancellation of the de current induced magnetic fluxes, hence the de unbalance current capacity is reduced. The unbalance capacity becomes half of the established rating since current flows through both halves of the propulsion winding. In addition, the current capacity of the bond is also one-half of the established unbalance capacity.

Case 4 is similar to 3 except that the current flows through one turn instead of two. The bond will handle the established unbalance current rating.

A typical application of an audio frequency style minibond system is shown in Figure 3-3. The center tap on each bond is shown unconnected, however in certain applications the tap may be used for connections to other bonds on the same or adjacent tracks.

TO TRANSMITTING

EQUIPMENT

N/C N/C

TO ---1------. RECEIVING EQUIPMENT

Figure 3-3. AF-Mini Impedance Bond - Circuit Application

6352, p. 11

UNION SWITCH .& SIGNAL

3.2 DESIGN CONCEPTS

3.2.1 General

I Figure 3-4 shows a general schematic for Tuned Minibonds N451486-0701 and N451486-0702. Tuned Minibond N451486-0701 circuit differences are shown by dashed lines and data in ( ). These bonds are tuned to three frequencies: cab transmitter, track transmitter and track receiver. The track winding is common to all the toroids. The high voltage terminals of each toroid is the inductor of a parallel resonant circuit.

Figure 3-5 shows an equivalent circuit of Figure 3-4. The resonant circuits have been reflected to the low voltage terminals of the toroidal coils.

3.2.2 Bond Impedance Across the Track Terminals

The inductance of the track winding is around one micro-henry. The reactance across the track terminals will be very low in the audio-frequency range. A value of 0.03 ohms would be typical at 5000 Hz. The impedance can be increased by tuning the winding. Tuning a secondary winding instead of the track winding allows use of smaller capacitors. High impedances require high circuit •o•s 0 and will only occur near the resonant frequency.

The tuned minibond has three parallel resonant circuits connected in series. The impedance across the track terminals will be the vector sum of the reflected impedances of each resonant circuit. The reflected impedances add (as in series instead of parallel) because induced voltages are proportional to the change in flux through its winding. The cores of all the resonant circuits pass through the track winding, hence the track winding sees a total flux equal to the sum of the individual core fluxes. Current passing through the track winding will cause a voltage drop across the terminals. The voltage will be transformed to the secondaries. The power imparted to each secondary will be determined by the ratio of the secondary reflected impedance to the total reflected impedance. The voltage impressed across each secondary will depend on:

a. the secondary reflected impedance.

b. the turn ratio between that secondary and the track winding.

When the impedances of all the resonant circuits are low, the impedance across the track terminals will be low. If the impedance of even one of the resonant circuits is high, then the impedance across the track winding will be high. An exception to this is when two or more high impedance resonant circuits develop a series resonance between them. In this case, the vector sum of the reflected impedances will be low.

6352, p. 12 (ReV. 6/87)

--~ (1) <: . "" ' CD -.I

"" w V1 N .. 'O . i--' w

'>;! I-'· lC c: H (1)

w I

.i:,. . i-'3 c: ::l (1) 0..

::s: I-'· ::l I-'· O' 0 ::l 0..

Ci) (") ::," (1)

!3 OJ rt' I-'· (")

r--------------------------------------------I CAPACITANCE APPROXIMATELY -,

I I I I I I I I I I I I I I I t I I I I I

2

= 1/((2 1r f)2l) :

t' 'TO BE 4 f1 =3900

DETERMINED' I f2•3660 I ~~~~E I TO RAIL 3 f4 t f3=3370 I

, REQUIRED • 207 8

f4 •31 00 : PlN f5=2820

O·coNNECTION 11111 155 t-1 I I I I I I J ~Em~ I

CENTER TAP

THE TRACK WINDING IS COMMON TO ALL CORES

EXCEPT COUPLING

TRANSFORMER CORE.

III C HERTZ>

TOTAL CAPACITANCE= SUM OF CAPACITANCE

r------------'IN THE CIRCUIT FROM

m 10W

LEFT TO RIGHT

550:132

TO WAYSIDE

,Ill I • (7J • e fg

I _J (150)

L3 L4

t L_, • • • • • • I

I TO RAlL

10.65 MH

10.65 MH

3n 25W

I • I • ~

L--------------------------------------------~ NOTE: MINIBOND N451486-0701 CIRCUIT DIFFERENCES SHOWN BY DASH LINE AND DATA IN ( ). JUMPER CONNECTION BETWEEN L2 AND L3 USED ON -0702 ONLY. ALL OTHER DATA COMMON TO BOTH -0701 AND -0702.

c z 0 z I ~ ::c QI (I)

c5 z )> r

ea

m UNIQN SWITCH St SIGNAL

155 • II TRACK

RECEIVER ,... , I I L J

6352, p. 14 Figure 3-5. Equivalent Circuit of Figure 3-4

UNION SWITCH & SIGNAL m 3.2.3 High "O" Parallel Resonant Circuit

The following discussion assumes knowledge of parallel resonant circuit characteristics. Figure 3-6 illustrates the general characteristics of a parallel resonant circuit having a high circuit "0°. Figures 3-7 and 3-8 illustrate relative impedance characteristics of three high "o• parallel resonant circuits having (1) different resonant frequencies and (2) non-overlapping bandwidths.

Refer to Figure 3-7. Note that the impedance at the res9nant peaks is much greater than the impedances between the peaks. The impedance at a peak of one circuit is much larger than the sum of the magnitudes of the other circuit impedances.

Refer to Figure 3-8. Note that between the resonant peaks some curves are positive and some are negative. If these impedances were connected in series, they would tend to offset each other.

3.2.4 Series Connected High "0° Parallel Resonant Circuits

Figure 3-9 illustrates the magnitude of the impedance for the three parallel resonant circuits of Figures 3-7 and 3-8 connected in series. Note that this curve appears similar to Figure 3-7. It is possible that the impedance peaks will occur at frequency values slightly different than those in Figure 3-7.

Between resonant peaks, the parallel resonant circuit contributes reactive impedance of opposite sign. At particular frequencies, series resonance will occur. Such resonance will occur once between peaks.

3.2.5 Minibond Impedance Versus Frequency Analysis

a. View from Track Terminals

Refer to Figure 3-5. The coupling transformer is connected in parallel to the series network of parallel resonant circuits. Signals from and to the wayside cable are coupled through this transformer. If this transformer impedance was sufficiently low, the impedance across the track terminals would also be low. Figure 3-10 shows the circuit viewed from one resonant circuit.

Note that if a series resonance occurred in the right circuit branch, a low impedance would also be produced across the track terminals. A series resonance occurring near one of the parallel resonant frequencies is not acceptable. The design of the coupling transformer prevents such undesirable resonances from occurring.

The coupling transformer is designed to have a relatively large impedance, and will have little effect on tuning of the resonant circuit coils. Any shift that does occur is compensated for during factory test.

6352, p. 15

B:l UNION SWITCH & SIGNAL

MAGNITUDE---

+ Z OHMS

FREQUENCY (Hz)

+

Z=R+jX

X POSITIVE IS INDUCTIVE X NEGATIVE IS CAPACITIVE

I BANDWIDTH I

Note that: 1. Z has an Inductive component when f<fr 2. Z has a capacitive component when f> fr 3. Z has no reactance at f = fr 4. fr = 1/(2n (LC) 1/2) for high "Q"

5. at resonance Z = w2L 2/R = Owl = URC

IMPEDANCE VERSUS FREQUENCY, TYPICAL HIGH "Q"

I --i

------ REAL PART

....___ ___ REACTIVE Z

6. When parallel resonance occurs, the loop current sees series resonance.

7. w = 2rr f

6352, p. 16 Figure 3-6. Parallel Resonant Circuit

1 z

OHMS

FREQUENCY (Hz)

I REACTIVE Z

OHMS

-FREQUENCY (Hz)

I -I

I

•,1

I I '4 BANDWIDTH ...I I - I

fr2

I I (..,, BANDWIDTH..., I I

UNION SWITCH & SIGNAL m fr3

I l"'-1

Figure 3-7. Impedance Versus Frequency

CIRCUIT #1

CIRCUIT #2

CIRCUIT #3

Figure 3-8. Reactive Impedance Versus Frequency

6352, p. 17


6352, p. 18

1 Z OHMS

-FREQUENCY (Hz)

TRACK TERMINALS

II

I I I- _J I I

BANDWIDTH

fr2

I 1 _ _J I I

BANDWIDTH

fr3

I I L __I I I

BANDWIDTH

Figure 3-9. Impedance Versus Frequency Three Circuits in Series

II

Figure 3-10

CABLE TERMINALS

Circuit View From One Resonant Circuit

3.2.6

UNION SWITCH & SIGNAL m b. View from Wayside Terminals

Figure 3-11 shows the impedance bond reflected to the cable terminals. The resonant circuits will short the coupling transformer except when one or more circuits have a high impedance, or when the left branch exhibits a parallel resonance with the transformer. Again, the design of the coupling transformer prevents it from resonating in the frequency range of interest for AF signaling.

c. Compensation for Cable Capacitance

Minibonds are tuned with a 0.1 MFD capacitor across the wayside cable terminals. This is to account for the maximum capacitance expected from the twisted pair cable. In the field, during initial.track circuit adjustment, a capacitor will be added in parallel with the cable as required so that the total capacitance is 0.1 MFD.

Conclusions and comments

a. There will be one resonant frequency for each parallel resonant circuit. No additional parallel resonance will occur in the desired frequency range.

b. Factory tuning procedures compensate for the effects of one circuit upon another and for the 0.1 MFD capacitance expected in field application.

c. Factory testing procedures check each bond for proper tuning and impedance.

c. In theory, resonant frequencies at the cable terminals will be the same as those at the track terminals.

6352, p. 19


• II

r- , I I L J

• II

r , I I L .J

• CABLE

II TERMINALS

r , I I L .J

Figure 3-11 Impedance Reflected To Cable Terminals

6352, p. 20

UNION SWITCH & SIGNAL m SECTION IV MAINTENANCE

4.1 FIELD INSPECTION AND MAINTENANCE

WARNING

TO AVOID PERSONAL INJURY WHILE MAINTAINING OR REPLACING IMPEDANCE BONDS, BE SURE TO DISCONNECT PROPULSION AND SIGNAL CURRENT IN THE WORKING AREA.

No disassembly or internal repairs shall be attempted on any impedance bond if trouble is suspected. A defective bond unit must be returned to the manufacturer as shipped. Field maintenance shall consist of periodic visual inspection of the bond for a cracked bond and bent, loosened and corroded terminals. Corroded terminals may be cleaned (with appropriate abrasive materials) and cable lugs retightened, however, in the event of case or terminal damage as specified above, the complete bond should be returned to the manufacturer.

All cables should be inspected for possible impact damage or fraying due to corrosion, and replaced if such problems are found. Tightness of various tie hold-down screws should also be checked to make sure the bond is held securely to the ties.

4.2 SHOP MAINTENANCE

4.2.1 Troubleshooting

a. Types of Failures

1. Loss of impedance

(a) Component failure ( 1) Short (2) Open

(b) Broken wire

(c) Bad or poor connection(s)

2. Impedance increase

3. Intermittent

b. Determining the Cause of Failure

Information is provided below to assist the user in troubleshooting and repair of the tuned minibond if the user so desires. However, return of the tuned minibond to the factory is recommended.

6352, P• 21


1. sweeping the Frequency to Find Peaks

The best method to analyze bond failures is to test the bond in the circuits of Figure 4-6 or 4-8. A source voltage is applied and then the frequency is swept through the audio frequency range. Voltage peaks across the wayside terminals or the track terminals are noted. These peaks should occur at or near the tuning frequencies of the tuned minibonds. There should be three peaks.

The absence of all peaks indicates one or more of the following:

(a) shorted coupling transformer (b) broken wire in the bond (c) loss of connection (d) track winding shorted (e) open winding in the coupling transformer (f) incorrect wiring

DC continuity tests can be used to check cases "b", "c•, and "en. A continuity test can also determine if the track winding is shorted if the center-tap joint is insulated. For cases "b 0 and "e" the coupling transformer primary winding must be disconnected from bond leads Sl and S2.

Case "a" can be tested by bypassing the coupling transformer. If the peaks now appear, then the transformer was the problem.

The presence of one or more peaks indicates that the problem lies in the resonant circuits. The absence of a peak during a frequency sweep indicates which circuit(s) is (are) causing the problem.

2. Impedance Increase

Due to the nature of the design in the Tuned Minibonds, an increase in impedance can occur in two ways.

{a) The series "Q" spoiling resistor(s) of the resonant circuit in question has decreased in value (i.e. shorted) or parallel "Q" spoiling resistors have an open connection or an increase in value.

(b) Component failure of one resonant circuit shifts the tuning of that circuit to a resonant frequency near the resonant frequency of another circuit. This type of failure would cause an impedance loss at the original resonant frequency of the circuit shifted.

3. Resonant Circuit Impedance Loss

Some possible causes:

(a) Increase in "Q" spoiling resistor(s) (b) poor connections (c) shorted capacitor(s) (d) open capacitor(s) (e) shorted coil ( f) open coil (g) broken wire (h) incorrect wiring

6352, p. 22

UNION SWITCH & SIGNAL m Disconnect all the resonant circuit coil leads and make a continuity test across the coil leads. This checks for case "f•.

If the coil is not open, then connect one of the coil leads and make a de continuity test across the remaining coil lead and its connection point. The test should be applied until a stable reading is obtained, since circuit capacitors will draw current until they are charged. If continuity exists, then capacitor(s) is (are) shorted (case "c").

For the remaining cases, measure the component values and compare them against what they should be as listed in Table 4-1.

c. Repair of the Determined Failure

1. Coil: The bond cannot be repaired unless the failure is due to a broken accessible lead.

2. Capacitors can be replaced. Consult the parts list for capacitor information. Replacement requires a tuning check and possibly an adjustment. The larger the capacitor value, the more likely an adjustment will be required.

3. Resistor(s): Check parts list and replace as required. Note the resistance values originally used or else impedance adjustments may be necessary.

4. Poor connections should be cleaned and/or tightened.

5. Broken wires should be replaced.

6352, p. 23

1::1::3 UNION SWITCH & SIGNAL

Table 4-1. Component Values

Resonant Circuit * Coils Approximate for Resonance Type Pins Inductance Typical Q

Capagitance (Millihenries) **

Frequency (X 10- Farads) (Hertz)

Cab Transmitter 5-6 5.80 +0.15 50 0.21095 4550 -Track Transmitter 7-8 5.33 +0.15 58 0.31245 3900 Track Transmitter 7-8 5.33 +0.15 58 0.35477 3660 Track Transmitter 7-8 5.33 +0.15 58 0.41846 3370 Track Transmitter 7-8 5.33 +0.15 58 0.49453 3100 -Track Transmitter 7-8 5.33 +0.15 58 0.59761 2820 Track Transmitter 7-8 5.33 +0.15 58 0.71396 2580 Track Transmitter 7-8 5.33 +0.15 58 1. 0776 2100 Track Transmitter 7-8 5.33 +0.15 58 1. 3165 1900 -Track Receiver 2-4 ll.02 +0.15 69 0.15ll2 3900 -Track Receiver 2-4 11.02 +0.15 69 0.17159 3660 Track Receiver 2-4 11.02 +0.15 69 0.20239 3370 Track Receiver 2-4 11.02 +0.15 69 0.23919 3100 Track Receiver 2-4 11.02 +0.15 69 0.28904 2820 Track Receiver 2-4 11.02 +0.15 69 0.34532 2580 Track Receiver 2-4 11.02 +0.15 69 0.52122 2100 Track Receiver 2-4 11.02 +0.15 69 0.63672 1900 -

* Measured at 1 volt, 1000 Hertz, at 2ooc.

** Measured with 0.25 amperes, 1000 Hz through winding at 20°c ambient resonant frequency= fr= 1/(2 LC) L = inductance, C = Capacitance

6352, p. 24

I

I

UNION SWITCH & SIGNAL b':J 4.2.2 Tuning

a. Test Equipment

b.

1. Frequency counter 2. Sine Wave Generator 3. Power Amplifier, Audio Frequencies, 16 ohm output 50 watt 4. Impedance Matching Transformer (W-400, N451428-0103) 5. lOK Ohm, 20 watt Resistor, Carbon 6. 15 Ohm, 24 watt Resistor, Carbon 7. 0.1 MFD capacitor J709145-0540 or J709145 8. Capacitor decade box(es) 200 volts ac rating, range .0001 to 0.1 MFD

(.0001 MFD/step) 9. scope with maximum capacitance 100 picofarads, minimum impedance 1 meg. 10. AC voltmeter, 4 digits, same qualifications as Item 9 11. Capacitor clip board 12. Various jumpers

General

This section outlines the procedure to be used to tune Minibond N451003-1101 or -1102 with its Coupling Unit N451003-1201 or -1202 respectively. Once tuned, a bond and its Coupling Unit will be considered a matched set.

The procedure is to tune a parallel by adding or removing capacitance. frequency to the circuit of Figure maximum voltage (V3) is obtained.

resonant circuit to the desired frequency This is done by applying the desired

4-1 and varying the capacitance until

,,...-...,...-.------,,~ PARALLEL RE'501'JANC:.E

DESIR'E.O FRt:QUENC.. '( l""\J

t- I C.l~CUIT

I ___ J

Figure 4-1. Basic Tuning Circuit

Once tuned, the capacitors will be permanently affixed.

Additional resonant frequencies are obtained by adding more capacitance to the circuit of Figure 4-1. The additional capacitors are connected by jumpers (Figure 4-2). Increasing the capacitance will decrease the resonant frequency.

(Rev. 5/87) 6352 I P• 25

e13·· UNION SWtT¢J,f & SIGNAL

2ND OES\REO FREQUENCY

JUM?ER

Vz

Figure 4-2. Adding Capacitance

The bond and Coupling Unit will contain three parallel resonant circuits. Two of the three circuits will be tuned for eight different frequencies. The remaining circuit will be tuned for one frequency (see Figure 4-3 for illustration}.

TO TE~T

CIRCUIT

TO TEST CIRCU\T

TO TE$"T CIRCU\T

6352, p. 26

Note: Capacitor labels shown are for example only. For actual lables see Figures A-3 and A-4.

Figure 4-3. Three Parallel Resonant Circuits


The customer makes the final frequency selection by disconnecting the appropriate jumper.

In practice the capacitors illustrated in Figure 4-3 will consist of three or four capacitors connected in parallel and soldered in place on both sides of a printed circuit board (see Figure 4-4).

TO TE~T

ClRC.U\"T

Figure 4-4. Actual Tuning Configuration

S\OE. VIEW

Due to tolerances, the capacitance required for individual bonds will vary. This section contains tables which approximate the amount of capacitance needed to obtain the desired resonant frequencies. Tuning can be accomplished without the tuning tables by applying the following equation.

fr= 1 = (¢)=

-1 (~) vrZ

-z 2 '7r

fr resonant frequency L = coil inductance c = capacitance

Note that increasing the capacitance will decrease the resonant frequency. Decreasing the capacitance will increase the resonant frequency.

Due to high voltages, PCB N451605-3201 requires placing two capacitors in series. The capacitors are to be equal in value. The effective capacitance is 1/2 the value of one of the capacitors used.

6352, p. 27

~ UNION SWITCH & SIGNAL

l I ----~ ,001 MFD

I I I .001 MFO

1I ___ _J

Figure 4-5. Cab Transmitter Tuning

Example: If an additional .0005 MFD is required, it is achieved by (1) placing two .001 MFD's in series, (2) placing the two in parallel with the other capacitors

(Figure 4-5).

c. General Tuning Procedure

1. The tuning of the PCBs will proceed in a specific order; N451605-3101 will be first, N451605-3102 will be second and N451605-3201 will be done last.

2. PCBs N451605-3101 and -3102 must be tuned to eight frequencies. Tuning of the PCBs will be done in the following frequency order; 3900, 3660, 3370, 3100, 2820, 2580, 2100 and 1900.

3. PCB N451605-3201 is to be tuned to 4550 Hz.

4. The tuning procedure to be used is given in Section 4.2.2.d.

Note

PCBs which are not being tuned are preset to a specific frequency. This will produce an average amount of interaction between circuits.

PCBs are identified with a stamped part number.

d. Specific Tuning Procedure

1. For a given capacitor PCB and frequency, wire the circuit of Figure 4-6 per Table 4-2 (Ref. Sect. 4.2.2.c Note).

2. Adjust the frequency generator to the desired frequency.

6352, p. 28

UNION SWITCH & SIGNAL El3 3. Adjust the source voltage to obtain tabulated Vtc/2 for Vtc•

4. Using the capacitor decade box, add or remove capacitance until a voltage peak is found for Vtc (the scope or digital voltmeter reading).

5. Adjust the voltage to obtain tabulated Vtc for Vtc•

6. Vary the capacitor decade box to find the voltage peak.

7. Add capacitors to the capacitor clipboard which approximate the value on the decade box. Tables 4-3 and 4-4 are provided as guides. When tuning PCB N451605-3201, two capacitors in series are required (Ref. Section 4.2.2.b). The capacitor values will be twice the value of the decade box.

8. Set the decade box to zero.

9. Repeat steps 5 thru 8 until changing the capacitor decade box only decreases the voltage.

10. Remove the decade box from the circuit.

11. With Vtc set to the tabulated value, vary the frequency until a voltage peak is obtained. This frequency should be within the tabulated tolerance of the desired frequency.

12. Remove the capacitors from the clipboard and secure to the capacitor PCBs in the positions tabulated. Solder capacitor leads to the turret lugs and trim excess lead length.

6352, p. 29

°' w u, N .. 'O • w 0

r--------------------------------------------, EE I I i I R .R I ~ I SIGNAL POWER I 6° I I I GENERA TOR AMPL l Fl ER OUTPUT I ~

II LI TO POSITION 6,3 OR 4 II : PER TABLE 4-2 c5

I FREQUENCY L2 TO POSITION 8,4 OR 6 I ~ I COUNTER PER TABLE 4-2 I r

II <OPTI ONAU II '-:tJ L3 L5 ~- I VOLTMETER CAPAC I TOR CAPAC l TOR I s::: 4 D l GI T SCOPE CLI P ~ I IO MEG, INP. L4 LG DECADE BOX BOARD I

I I 'j I I I I I ;" . I TO POSITIONS} {TO POSITIONS TO POSITION @ @ I

B, 4 OR 6 7, 2 OR 5 :: L10 :;:: I PER TABLE 4-2 '' ,, PER TABLE 4-2 PER TABLE 4-2. ,, w I ~- I L7 L8 I I-'•

~ I GREEN fO I t:J I I ow I ~- I RED I ~ I I ~· I w BLUE I

t:) ~ LLJ

i31 I ~ ~ ~ WHITE/BLACK STRIPE I ,, I ~ ~ ie 30 JUMPER LEAD I p; I 25W I tr f--' I I ro ~ .t,. I l::E: l I 1<1?

0 I I~ I ·1m I I~ ::E: I \ ~ I \ I" I \ ~ I N451605-3102 N451605-3101 N451605-320t J70C3145-0540 I~ I !TEMPORARY> l::E:

L--------------------------------------------~~

Cl'\ w u, N ..

'"O

w .....

8 Ill 0-..... (1)

""' I N . :;;: I-'• ,., I-'· ::i

l.Q

8 Ill 0-..... (1)

Hl 0 ,., l"lj I-'·

l.Q s:: ,., (D

""' I Cl'\

Tuning of Lead Positioning

Board

N451605- Ll L2 L3 & LS L4 & L6 L7 L8 L9

11 n1 6 8 7 8 1n 8 11

3101 6 8 7 8 10 8 11 3101 6 8 7 8 10 8 11

3101 6 8 7 8 10 8 11

3101 6 8 7 8 10 8 11

3101 6 8 7 8 1 (I 8 11

3101 6 8 7 8 10 8 11

1101 6 8 7 8 10 8 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 .2 4 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 2 4 11

3102 3 4 2 4 2 4 11

3201 4 6 5 6 9 6 11 * V • voltage across leads L3 & L4 = LS & L6. tc ** Front and back positions may be used if empty •

LlO

12

12

12

12

12

1?

12

12

12

12

12

12

12

12

12

12

13

Note: Frequency selection is discussed in Section II.

Board (Hz) N451605-3101

Set To Tol.

3900 ±.5 +

3660 -s

3370 ±.s

3100 ±.5

2820 ±.5 +

25Rfl -s +

2100 -5

lQfl(I ±5

3100 NA

3100 NA

3100 NA

2820 NA

3100 NA

3100 NA

3100 NA

3100 NA

3100 NA

* * * Board (Hz) vtc Capacitor N451605-3102 Placement

Set To Tol. (Volts) Pos. Board

3100 NA c;1_. 0 C7 rR 11()1

11 "" NA c;1_. 0 ("', ("(. 31 01

3100 NA 44.2 C3. C4 3101

28?fl NA 17 8 ("1 r? 3101

3100 NA 31. 2 CQ r1 n 31 fl1

11 "" NA ?<; c; Cll . r1? 1101

3lflfl NA 2'i 5 Cl 1. rl L,. 11 fl1

'l 1 "" ll!A ?<; 'i Cl'i CH, 1101

3900 ±.'i 12 g4 C7. CB 110?

3660 ±.5 12.94 CS. C6 3!Q.L_ 3370 + -s 12.94 C3, C4 3102

+ 3100 -s 12.94 Cl, C2 3102

2820 .±.5 12.94 C9 ClO 3102

2580 + -s 12,94 Cll. C12 3102

2100 + -s 12.94 Cl3, Cl4 3102 +

1900 -5 12.94 ClS Cl6 3HI?

3100 NA 75.0 All 3201 NA• Not Applicable

c z 5 z I ~ :x: QI Cl)

c5 z )> r

e3


6352, p. 32

MFDs Required

.00025 - .00075

.00075 - .00125

.00125 - .00185

.00185 - .00275

.00275 - .00380

.00380 - .00450

.00450 - .00520

.0052 - .0060

.0060 - .0065

.0065 - .0073

.0073 .0080

.0080 - .0087

.0087 - .00945

.00945 - .00985

.00985 - .0105 • 0105 - • 01125 .00125 - .01185 • 01185 - • 01275 .01275 - .01415 .01415 - .0155 .0155 - .01625 .01625 - .01685 .01685 - .0178 .0178 - .0190 • 0190 - .0204 .0204 - .0215 .0215 - • 0225 .0225 - .0235 .0235 - .0240 .0240 - .0248 .0248 - .0259 .0259 - .0277 .0277 - .0290 .0290 - .0310 .0310 - .0325 .0325 - .0347

Table 4-3

Capacitors

.0005

.0010

.0015

.0022

.0033

.0010 & .0033

.0047

.0047 & .001

.0047 & .0015

.0068

.0068 & .001

.0082

.0082 & .0010

.0082 & .0015

.01

.01 & .001

.01 & .0015

.01 & .0022

.01 & .0033

.015

.015 & .001

.015 & .0015

.015 & .0022

.015 & .0033

.015 & .0047

.015 & .0068

.022

.0220 & .001

.022 & .0015

.022 & .0022

.022 & .0033

.022 & .0047

.022 & .0068

.015 & .0150

.0220 & .0100 .0330

Capacitance

• 001 .0015 .0022 .0033 .0047 .0068 .0082 .0100 .0150 .0220 .0330 .0470 .0680 .0820 .1000 .1500 .2200 .3300

Table 4-4

UNION SWITCH & SIGNAL w Part No •

J709145-0576 J709145-0577 J709145-0578 J709145-0579 J709145-0580 J709145-0581 J709145-0582 J709145-0583 J709145-0584 J709145-0585 J709145-0586 J709145-0587 J709145-0588 J709145-0589 J709145-0590 J709145-0591 J709145-0592 J709145-0593

Capacitors are polypropylene, 270 volts rms, +2% tolerance.

6352, p. 33


4.2.3 Bond Assembly

a. Final Assembly/Test

1. Spray coating of new capacitors is recommended, using a spray suitable for printed circuit boards.

2. Secure capacitors to printed circuit boards using a non-corrosive R.T.V. adhesive (US&S part no. J041943).

3. Assemble PCBs into Coupling Unit and wire per wiring diagram of Figure 4-7 except the buss wire.

4. Assemble circuit of Figure 4-8 with components in the box.

5. For each board and frequency:

6.

7.

(a) Connect circuit components per Table 4-5.

(b) Verify, at tabulated Vtc, that a resonant voltage peak exists at the desired frequency per tabulated tolerance in Table 4-5.

(a) Set PCB N451605-3101 at 3370 Hz by using jumpers.

(b) Set PCB N451605-3102 at 1900 Hz by using jumpers.

(a) Connect leads as follows:

Lead Position

L9 15 L2 14 L3 5 L4 6

(b) Measure and record the resistance of the 15 ohm resistor.

8. Apply 4550 Hz to circuit. Adjust voltage across L3 and L4 to 75.0 volts by adjusting the source voltage.

9. Measure voltage across positions 14-16 and 15-16. Calculate the impedance. The impedance shall be 1.15 ohms+ 15%.

10. Place lead L3 at position 7. Place lead L4 at position 8.

11. Apply 3370 Hz to circuit. Adjust voltage across L3 and L4 to 44.2 volts.

12. Measure the voltage across positions 14-16 and 15-16. Calculate the impedance. The impedance shall be 1.01 ohms + 15%. -

13. Place lead L3 at position 2.

Place lead L4 at position 4.

6352, p. 34

.......

& <:

O'\ ........ 0:, -...)

O'\ w u, N ... 'O . w u,

C) .i:,,. \J1 -(J'I _.,. 0 I

N N

::0 (D

< . 0

".1 I-'•

LQ c ~ Cl)

""' I -...) . 1-3 c ::s Cl)

0..

:;;:: I-'• ::s I-'• 0-0 ::s 0..

~ I-'· ~ I-'· ::s

LQ

i::, I-'· OJ

LQ ~ OJ 3

I N451486·0701, ·0702 WIRING DIAGRAM ~-=======;::~;:: t AX A)( )C X: )(:. a ii XX X •, /"1~A §,. §. )(§l(§j(§l(§l(~X~X~ll§l(§...,

_8

Pins_/ of pin connector

z ...., ...., ex (::,

I

SLOTTED END

i EB 1

.n

EB

WAYSIDE CABLE ,..:;

u

I ~ GO

,..:; u ,c ..., tJ!I

N451605-3102 !RECI

I

N451605-3101 !TRANS I

N451605-3201 IC AB I

WARNING HIGH VOLTAGE Do not adjust or remove printed circuit boards unless the power is off. Power can be supplied through the wayside cable or the rail connections of the bond.

FREQUENCY SELECTION - cut buss wire segments.

NOTE: * Used with N451486·0701 only. ** Used with N451486-0702 only.

L &. Used In place of jumper on N451486·0701 only.

...., t: ::c ~ EB 7

WAYSIDE CABLE

• N451003·1101 *

OR

N451003·1102**

• COUPLING UNIT

N451003·1201 *

OR

N451003·1202**

~ 4,-

D -$- •

1900 HZ NO CUT REQUIRED.

I

c z 6 z I ~ :.c Rt c:n ci z > ,.. _J ~

w UNION SWITCH & SIGNAL

14. Apply 1900 Hz to the circuit. Adjust the source voltage to obtain 12.94 volts across leads L3 and L4.

15. Measure the voltage across positions 14-16 and 15-16. Calculate the impedance. The impedance shall be .942 ohms+ 15%.

Note: Impedance= VzR/VR where:

R = resistance of the 15 ohm (approx.) resistor.

Vz voltage across the bond (positions 14-16).

VR = voltage across R (positions 15-16).

16. Adjust jumpers to select desired frequency group, close and fasten doors.

b. Impedance Adjustment

If the impedance is found to be too high, use a decade resistance box connected across the tuning capacitors to purposely reduce the "Q" factor of the coils. Using the highest resistance found, solder a fixed l watt resistor across the turret lugs and verify the impedance. If still too high, use a slightly lower resistance value. On the N451605-3201 PCB, two resistors of the same value are to be used in series. Resistors are to be selected from the carbon composition 1 watt listing below. Values other than those listed can be used.

US&S Part Numbers

8.2 K - J721271 10 K - J720852 15 K - J721188 20 K - J721137 22 K - J720903 30 K - J721182 33 K - J720854

6352, p. 36

O'\ w U1 N ...

'O . w '3

"XJ ..... c.Q c l"I (I)

,I», I

co . ::.:: ..... l"I ..... ;::s

c.Q

CJ ..... Sll

c.Q l"I Sll s Hl 0 l"I

>-:l Sll tr 1--' (I)

,I»,

I U1

r--------------------------------------------, I 14 f I I I SIGNAL POWER 160 I I GENERATOR AMPLIFIER OUTPUT I I I..P I I O I I FREQUENCY I I COUNTER I

I CABLE TO f I L3 LS ClRCUIT CJ I I VOLTMETER BOARDS I I IO tEDd_Gl{NP. L4 L6 SCOPE ~---- I I I

I TO POSITIONS} tTO POSITIONS II I 7. 3 OR 6 8. 4 OR 5 2 I PER TABLE 4-5 v ,, PER TABLE 4-5 4W I I I I GREEN JO I I IOW I I RED I I I I

w BLUE I (!) :i.:: La.l

I ~ ~ :: WHITE/BLACK STRlPE I a:: ....J :x: I I o co 3: 30 JUMPER LEAD

1 25W I

I I I I I TT I I I I I I I I 1 ~ I ' ' I o I \ I ; I \ I =t I \ I ~ I N451605-3102 N451605-3101 N451605-3201 J70q145-0540 I ~ I (TEMPORARY> I ~

L -------------------------------------------Jr EE

°' w u, N ... 'O

w co

8 Ill O"' ..... (1)

.i::,. I u, . :::E:; I-'· H I-'• ;::)

<.Q

8 Ill O"' ..... (1)

Hl 0 H

"1 I-'•

<.Q c H (1)

.i::,. I

co

Check of Lead Positioning

Board

N451605- Ll L2 L3 & LS L4 & L6 L7 LS L9

3101 - 14 7 8 - - 15

3101 - 14 7 8 - - 15

3101 - 14 7 8 - - 15

3101 - 14 7 8 - - 15

3101 - 14 7 8 - - 15

1101 - 14 7 8 - - 1 <;

3101 - 14 7 8 - - 15

3101 - 14 7 8 - - 15

3102 - 14 3 4 - - 15

3102 - 14 3 4 - - 15

3102 - 14 3 4 - - 15

3102 - 11.. 3 4 - - 15

1107 - 1" 1 4 - - 15

3102 - 14 3 4 - - 15

3102 - 14 3 4 - - 15

3102 - 14 3 4 - - 15

3201 - 14 6 5 - - 15

* V • voltage across leads LJ & L4 • LS & L6. tc ** Front and back positions may be used if empty.

LlO

--------

--------

-

Note: Frequency selection is discussed in Section II.

Board (Hz) N451605-3101

Set To Tol.

3900 ±15

3660 ±15

3370 ±15

3100 ±15

2820 ±15

2580 + -15

2100 ±15

1900 ±15

3100 NA

3100 NA

3100 NA

2820 NA

3100 NA

3100 NA

3100 NA

3100 NA

3100 NA

* * * Board (Hz) v Capacitor N451605-3102 tc Placement

Set To Tol. (Volts) Pos. Board

3100 NA 51.0 - -3100 NA 51.0 - -3100 NA 44.2 - -2820 NA 37.8 - -3100 NA 31.2 - -3100 NA 25.5 - -3100 NA 25.5 - -3100 NA 25.5 - -

3900 ±15 12.94 - -3660 ±15 12.94 - -

+ 3370 -15 12.94 - -3100 + -1c; 12 q4 - -2820 ±15 12.94 - -2580 ±11.._ 12.94 - -2100 ±15 12.94 - -1900 ±15 12.94 - -

3100 NA 75.0 - -NA• Not Applicable

£B c z 0 z I ~ :c • (I)

s ~ r-

SERVICE MANUAL 6352 Appendix A

Parts List

AF-500 TUNED MINIBOND

July, 1985 (Rev. 7/87) ID0048F/DN0017F B-7 /87-40-2781-1

"RINTED IN USA

Part Numbers

N451486-0701

N451486-0702

UNION SWITCH & SIGNAL AMERICAN STANDARD INC • PO BOX 420 • PGH., PA 15230

AF-500 TUNBD MINIBOND PARTS LIST

Tuned Minibonds N451486-0701, -0702

Note: Minibond -0701 has been obsoleted and is no longer available for ordering. Replaced by -0702. Part numbers provided for maintenance only.

-0701 Item Part No.

Minibond (See Fig. A-1) N451003-ll01+ coupling Unit (See Fig. A-2) N451003-1201

** Track Transmitter PCB (See Fig. A-3) N451605-3101 ** Track Receiver PCB (See Fig. A-3) N451605-3102 ** Cab Transmitter PCB (See Fig. A-4) N451605-3201

* Capacitor, 0.033 MFD, 270 VAC J709145-0586 * Capacitor, 0.022 MFD, 270 VAC J709145-0585 * Capacitor, 0.015 MFD, 270 VAC J7 09145-0584 * Capacitor, 0.01 MFD, 270 VAC J709145-0408 * Capacitor, 0.0082 MFD, 270 VAC J709145-0582 * Capacitor, 0.0068 MFD, 270 VAC J709145-0581 * Capacitor, 0.0047 MFD, 270 VAC J709145-0580 * capacitor, 0.0033 MFD, 270 VAC J709145-0579 * Capacitor, 0.0022 MFD, 270 VAC J709145-0578 * Capacitor, 0.0015 MFD, 270 VAC J709145-0577 * Capacitor, 0.001 MFD, 270 VAC J709145-0404


-0702 Part No.

N451003-1102 N451003-1202 N451605-3101 N451605-3102 N451605-3201 J709145-0586 J709145-0585 J709145-0584 J709145-0408 J709145-0582 J709145-0581 J709145-0580 J709145-0579 J709145-0578 J709145-0577 J709145-0404

* Capacitors are used as required for fine tuning and placed on the printed circuit boards (PCB's).

** These items usually require adjustment to suit the particular minibond used. Replacement will usually require re-adjustment, and thus the units and minibond become a "married pair".

+ N451003-1101 obsoleted. Replaced with N451003-1102. Recommended changing N451003-1201 to -1202. (Requires new tag only.) This will upgrade N451486-0701 to a N451486-0702.

(Rev. 6/87) 6352, p. A-1


Minibonds, N451003-1101, -1102 (See Figure A-1)

Item Description Part No.

* 1 Mounting Bracket R451004-4803

* 2 •J• Bar M451004-4701

* 3 Coil & Core Assembly N451004-4901 4 3/4" Lockwasher, Sil. Bronze J475197 5 Nut, 3/4-10, Hex, Sil. Bronze J480304 6 Bolt, 3/4-10 x 2-3/4, Hex. Sil Bronze J460119 9 Nameplate M451607-4401

10 11a• Dia. Al. Pop Rivet J490029 15 3/4" Flat washer, Sil. Bronze J475196

* These items are partially or completely encapsulated and therefore not replaceable.

I Note: Minibond -1101 is obsolete and no longer available for ordering.

6352, p. A-2 (Rev. 6/87}

1---11 :1 I I I I

·~ I I T ---r-1 I I I I I I I I I I I I

+ I I I I I I

* I I I I I I I I I

I I I I ' I I I I I I ------,-- r - - - I I I I I

'I L1 ___ 1J

0451003-11 Rev. 4

I I I I I I I I I I

®

(Z) o/ie, IY\TC:.i.1401..~S(Ri.f.)

*MINIBONDS N451003-1101 OR N451003-1102

' \ I

/

1------------fJ-g- R.EF)

I I

'


(2) ;~ DIA.. ~OLES(R.EF.)

Figure A-1. Minibond Assembly

6352, p. A-3/4

Coupling Units N451003-1201 and -1202 (See Figure A-2)

Item

5 25 30 35 40 45 50 55 60 65 70 75 80 85 95 100 105 llO ll5 120 125 130 135 140 145 150 155 160 165 170 180 185 190 205 210 215

(Rev. 6/87)

Description

Box Nut, 8-32, Hex Stl. Stud #8 Lockwasher washer, Stl. Shock Mount, Stl. Screw, 6-32 x 3/8 Rd. Hd. Stl. #6 Lockwasher Nut, 6-32, Hex, Stl. Card file screw, Door Latch 1/4" Plate washer, Stl. washer Roll Pin Door Clamp PCB Guide Cable Grip Connecting Cable (See Fig. A-7) Retainer Screw, 10-32 x 7/16, Rd. Hd. Stl. UO Lockwasher #10 Flat washer Resistor, 1 ohm, lOW Screw, 2-56 x 5/16, Rd. Hd. Stl. #2 Lockwasher Nut, 2-56, Hex, Stl. Resistor, 3 ohm, 25 W Screw, 4-40 x 3/8, Rd. Hd. Stl. #4 Lockwasher Nut, 4-40, Hex, Stl. Terminal Faston Nameplate Rivet, Alum. Faston Terminal, Insul. Extruded Rubber Channel Tag

* -1201 Tag M451640-2201 -1202 Tag M451640-7101

UNION SWITCH & SIGNAL m Part No.

R451004-5501 J048166 M451173-0401 J047681 M388367-001 J751329 J525031 J047662 J048148 R451004-5002 M451488-0301 J047501 M073099 J487012 M451158-1202 J712097 J712005 N451458-3801 M451004-7901 J525038 J047715 J475077 J735519-0064 J525077 J047573 J480028 J735519-0514 J525074 J047765 J480006 J731066 M451607-4402 J490037-0010 J731477 A075084

*

6352, p. A-5/A-6

1

F451003-12 Rev. 2

(Rev. 6/8})

(roR REF. ONLY) f't') ~, OJA. H<><l!S

!+------ 4 l (RCF:)

I- -__________ 7

_, (RlF.) I

(RE-.) 2

UNION SWITCH & SIGNAL ti:,

+

4 i (REF:)

Figure A-2. Coupling Unit Assembly

6352, p. A-7/8

Track Transmitter PCB - N451605-3101 (See Figure A-3)

Item

10 30 35 40 45 50 Cl C3,9,10 C4 cs C6 C7 C8,15 Cll Cl3 Cl4

Description

Turret Terminal, Sold. Lug Faston Terminal, Male 1/8" Pop Rivet Turret Lug Turret Lug Extruded Rubber Channel Capacitor, 0.068 MFD, 270 VAC Capacitor, 0.047 MFD, 270 VAC Capacitor, 0.01 MFD, 270 VAC Capacitor, 0.033 MFD, 270 VAC Capacitor, 0.0047 MFD, 270 VAC Capacitor, 0.082 MFD, 270 VAC Capacitor, 0.22 MFD, 270 VAC Capacitor, 0.1 MFD, 270 VAC Capacitor, 0.33 MFD, 270 VAC Capacitor, 0.015 MFD, 270 VAC

Track Receiver PCB - N451605-3102 (See Figure A-3)

Item

10 30 35 40 45 50 Cl,8 C3 C4 C6,14 C7,15 C9,ll Cl3 Cl6

Description

Turret Terminal, Sold. Lug Faston Terminal, Male l/8n Pop Rivet Turret Lug Turret Lug Extruded Rubber Channel Capacitor, 0.033 MFD, 270 VAC Capacitor, 0.022 MFD, 270 VAC Capacitor, 0.0068 MFD, 270 VAC Capacitor, 0.015 MFD, 270 VAC Capacitor, 0.1 MFD, 270 VAC Capacitor, 0.0047 MFD, 270 VAC Capacitor, 0.15 MFD, 270 VAC Capacitor, 0.0082 MFD, 270 VAC


J731399-0006 J731468 J490049 J714159 J579797 A075084 J709145-0588 J709145-0587 J709145-0583 J709145-0586 J709145-0580 J709145-0589 J709145-0592 J709145-0590 J709145-0593 J709145-0584

Part No.

J731399-0006 J731468 J490049 J714159 J579797 A075084 J709145-0586 J709145-0585 J709145-0581 J709145-0584 J709145-0590 J709145-0580 J709145-0591 J709145-0582

6352, p. A-9

O'\ w u, N ..

'O . :i,. I

...... 0

'"Xj ..... l.Q c '"I (1)

:r w

t-3 '"I CJ (} ;,;-

t-3 '"I CJ ::i Cll :3 ..... rt rt <D '"I

R'>

~ (1) (} (1) ..... < <D '"I

~ () 0-

"' 310)( SOARO

COMPONENi "!,\OE

~ 0451605-31 Rev. 2 n ~

0 0 ~

TO CIRCl!lr SIJJEON FIN/Ii. TEST. -< /1!)1)/r/ONIIL Clll'IIClrORS TO BE 11.DlJGlJ

r-- --- - ,-(,o '

COMl'ONENT S!JJE SOUER ON ]JOTH SIDES.

Clll'IIC/TORS Cl THRIJCU,.

~G G I

r

f ~ I l. ; I L

= ... ... ...

= ..... ... ...

I L I L I L I L

C16[ ~--] C15[ .... ~]

C14[~- I C13[ ·1 C12[. ·····~~] Cll[ ... ..... ·- ~J

= ,~ ····~~~-1(:2 c10L I = ;;;

I lcl CJ J

L UN451605-31 REV.

= = "'

= = -...

= ... ... ...

= ... ... ...

1

_J

EB c z 0 z I ~ x a, fl> a; ~ ,...

Cab Transmitter - N451605-3201 (See Figure A-4)

Item

10 C2,6 C3,7 20 25 30 35 40 45 50 65 70

Description

Turret Terminal, Sold. Lug capacitor, 0.068 MFD, 270 VAC Capacitor, 0.33 MFD, 270 VAC Transformer Screw, 4-40 x 3/8, Rd. Hd. Stl. #4 Flat Washer #4 Lockwasher Nut, 4-40 Stl. Faston Terminal 1/8" Pop Rivet Faston Terminal, Male Extruded Rubber Channel


J731399-0006 J709145-0588 J709145-0593 N451039-4801 J525074 J047640 J047765 J480006 J731066 J490049 J731468 A075084

6352, p. A-11

O'\ w U1 N

'O

;)>I I

...... N

'-x:l I-'•

LO c H (D

;)>I I

""" n OJ ti

>-3 H OJ ::::s Cll El I-'• rt (1" (D H

'"O g

COMFONENT S/1)£

1./IRING OIAGRAM (COMPONENT SIOE)

45,

COMPOAll:NT SIJ)E

5

Vl£W SHOWING MO/JNTINIS OF Tfl!INS FOP.MER (Ti) TO THE PCB.

D451605-32 Rev. 4

TO Cl/iCIIJr SIDE ON FIA/AL Tl:ST -< IIDD/TIONIIL CAPIICtrORS TO ,8£ AJ)J)£.D

i--- --- ,-{JO .

SOLJ)E/1 ON l!,OTH SIDES,

Cl/l'AC!TOIU Cl THIWC8.

Ez c z 5 z ! ~ :c 11!1 tn

80 GJ GJ GJ GJ8 -$1

f•-c I I" " I 1 I La c1 I I I C2 cs I I LI C5 I

2P 2S

IP IS

L Tl

UN451605-32 _J REV.


r------------------------------- ------------,

CONNECT JON

1900 2100 2820

CIRCUIT PATHS

CAPACITOR COMMON

PATH Ql--~--+~~~~~~ ...... ~~--+~~--<.._~~---~~-.1.~~____.....--

I I I I I I I I I I I I I I I I I I I

COi.PONE NT I SlDE I

3660 3370

• = CAPACITOR MOUNTING TURRET LUG.

0 = BUSS WIRE MOUNTING TURRET LUG.

'--.../= BUSS WIRE SEGMENT JUMPER STRAP.

Ir\!. BUSS WIRE MOUNTING TURRET LUG WITH MALE M "FAST-ON" TERMINAL ON BACK OF P.C.B,

3100

I I I I I I I I I I I I

DIAGRAM VALID FOR CIRCUIT SlDE ALSO. : I ALSO SEE FIGURE A-3 I

L--------------------------------------------~ Figure A-5. Track Transmitter & Receiver Wiring Diagram

,--------------------------------------------1 I O I I I I I I O I I I I CB C7 C6 cs I I FEMALE O 2S I

"FAST-ON" IS I CONNECT I ON I I I I I I I I IP I I 2P I I C4 C3 C2 Cl I I O I I I I O I I I I I I I I I I ALSO SEE FIGURE A-4 I I I L--------------------------------------------~

Figure A-6. Cab Transmitter Wiring Diagram

6352, p. A-13

w UNION SWITCH & SIGNAL

Connecting Cable - N451458-3801 (See Figure A-7)

Item Description Part No.

5 Plug Connector, 90 Degree J709146-0196 10 Cable, 7 Cond. U6 AWG A045786 15 Fast on Terminal ( 5) J731066 20 Fas ton Terminal, Insul. (2) J731476

6352, p. A-14

~ (0 <:

O'I

' co -J

0\ w u, I\.) ..

'"O . :i,, I

....... u,

1-i:J I-'•

<.O s:: H (0

:i,, I

-J . 0 0 ::, ::, (0 (') l"1' ..... ;:I <.O

0 SlJ er I-' (0

3G, (~t:F.)

c •' ('

L _j

I~ ((5

COLOR

BLACK

R£IJ

ORANGE

GREEN

VIEW BLUE WHITE

C451458-38 REV 2 W-8K

~ IS)oll.@

'01\/1\/,P/i'J "L" TERMINATION

2 9 J73 I O!o!o 15 3 13 J 7'310/o(o < IS

4 q J731oc..a, 15

5 ,2 J1'3141G. 20

~ 13 J1310'-G. 11~ 7 6 J13141"' ''lr

8 13 J13\0(c,(c, Ci!)

c: z 0 z i ~ ::c RO en ci z )> r

EB

Documents

AF-500 TUNED MINIBOND - Global Product Support · SERVICE MANUAL 6352 Description, Operation & Maintenance AF-500 TUNED MINIBOND July, 1985 (Rev. 7/87) ID0048F/DN0017F B-7/87-40-2781-1