audio frequency train detection and cab signaling system …€¦ · train detection and cab...

SERVICE MANUAL 6149

AUDIO FREQUENCY TRAIN DETECTION AND CAB SIGNALING SYSTEM

AF-400

June, 1983 UNION SWITCH & SIGNAL DIVISION A-6/83-200-2503- 1 AMERICAN STANDARD INC./ SWISSVALE. PA 15218

m UNION SWITCH & SIGNAL

REVISION INDEX

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

Page Number Date of Revision Page Number Date of Revision

A

-

UNION SWITCH & SIGNAL ffi

TABLE OF CONTENTS

Section/Paragraph Page

I 1.1 1.2 1. 2 .1 1.2.2 1.2.3 1.3 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.5 1.5.1 1.5.2 1.5.3

II 2.1 2.2 2.2.1 2.2.2

III 3.1 3.2 3.2.1 3.2.2 3.2.2.l 3.2.2.2 3.2.2.3 3.2.2.4 3.2.2.5 3.2.3 3.3 3.3.1 3.3.2

IV 4.1 4.2 4.2.l 4.2.l.l 4.2.l.2

4.2.l.3 4.2.2

GENERAL INFORMATION •.•. PURPOSE OF EQUIP~.i.ENT ••.• SCOPE OF OPERATION .. . . . Track Occupancy Detection Function •••• Cab Signaling Function .•••••••••• Cab Berthing Status Function .•• PHYSICAL DESCRIPTION. • •••••••• SYSTEM COMPONENTS . • • . • .•••• Minibond ••••••••••• . . . . . . . . . . . Coupling Unit •.•• Power Supplies. • •• Vital Relays •• SPECIFICATIONS .••••• AF-400 Card Files ••..

. . . . . . System Equipment. • • •• Track Circuit ..••

SYSTEM APPLICATION • • • • • • • • . • INTRODUCTION • • • • • . • • TYPICAL SYSTEM LAYOUT •.••• Berthing Timer Application ..•. Code Rate Reference Interconnection

Between Locations •..••••••

INSTALLATION AND ADJUSTMENT ••••• INSTALLATION •.•••.••••. ADJUSTMENTS .••.••• Recommended Test Equipment • Adjustment Procedures Transmitter Bias Aajustment •••

. . . . . . .

. . . . . . .

Tuning Panel Adjustment ••••••• Receiver Synchronous Rectifier Adjustment Train Detection Signal Level Adjustment Cab Signal Level Adjustment ••.••• Records and Data • • • • • -· • • • • • • • • • • MINIMUM PERFORMANCE TESTS • • • . • •• Train Detection Test • Cab Signaling Test ••

FUNCTIONAL DESCRIPTION

. . . .

. . INTRODUCTION ••••••••••• FUNCTIONAL BLOCK DIAGRAM DESCRIPTION. Train Detection Function .•••••••••• Broken Rail Detection Subfunction Broken-Down Insulated Joint Detection

Subfunction ...••••.•••••• Interference Immunity Subfunction Cab Signal Transmission Function.

1-1 1-1 1-1 1-3 1-3 1-4 1-4 1-7 1-7 1-7 1-8 1-8 1-8 1-8 1-9 1-10

2-1 2-1 2-1 2-1

2-2

3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-3 3-4 3-4 3-5 3-6 3-6 3-9

4-1 4-1 4-1 4-1 4-3

4-3 4-3 4-4

i

ffi UNION SWITCH & SIGNAL

Figure

A-10

A-11 A-12

A-13

A-14

vi

LIST OF ILLUSTRATIONS {Continued)

Title

Line Transmitter/Receiver Printed Circuit Board Assembly (N451570-3101) •••••••••

Tuning Panel Assembly (N451052-3301) •••• Tuning Panel Printed Circuit Board Assembly

{N451522-8901) ..•••.•••.•••• Coupling Unit With Minibond Assembly

( N451003-09XX) • . • • • • • • • • • • • • Coupling Unit With Minibond Assembly

{N451003-10XX) •••••.••••••••

Page

A-27 A-29

A-30

A-32

A-33

UNION SWITCH & SIGNAL ~

LIST OF TABLES

Table Title Page

3-1 Recommended Test Equipment for System Adjustments and Tests . . . . . . . . . . . . 3-1

5-1 Cleaning Agents and Materials . . . . . . . . . . . 5-2 .. 5-2 Troubleshooting Symptoms • . . . . . . . . . . . 5-7 6-1 Recommended Test Equipment and Components for

Shop Maintenance . . . . . . . . . . . . . 6-1 6-2 Calibration Range for Code Rates . . . . . . . . . . 6-10 6-3 Code Rate Select vs. Train Detection Frequency

Amplitude . . . . . . . . . . . . . . . 6-15 6-4 Code Rate Select vs. Train Detection Frequency

Amplitude for 1590 Hz and 2670 Hz Only . . . . . . 6-15 6-5 Code Rate on-Time :or -8303 and -8304 PCBs at

13.6 Hz and 16.8 Hz . . . . . . . . . . . 6-16 6-6 Transmitter PCB Decade Resistance Values vs.

Frequency . . . . . . . . . . . . . . . . 6-20 6-7 Acceptable Ranges for AF-400 Transmitter RMS

Output Voltage . . . . . . . . . . . . . . 6-22 6-8 Train Detection Frequency vs. VRMS Modulation

Voltage . . . . . . . . . . . . . . . . . . . 6-22 6-9 Resistance Measurements on Transmitter Power

Transistor PCB . . . . . . . . . . . . . . . . 6-23 6-10 RTl Resistor Values vs. Frequency and Filter

Input Voltage . . . . . . . . . . . . . . 6-24 6-11 Code Rate Delay Time Adjustment . . . . . . . . . . 6-29 6-12 Berthing Timer On-Off Time Measurement . . . . . 6-41 6-13 Tuning Panel PCB Capacitance and Dissipation

Factor Measurements . . . . . . . . . . . . . 6-43 6-14 Coupling Unit Current Ranges vs. Frequency . 6-47

vii/viii

EQUIPMENT ROOM

TYPICAL POWER SUPPLY RACK

24 voe TRANSMIT PWR

24 voe OSCILLATOR PWR

24 VDC RECEIVER PWR

TYPICAL AF-400TW TRACK CIRCUITS RACK

TRACK CIRCUIT REPEATER RELAY ENABLE

BERTHING TIMER OUT

I ~-Y_s1_o_E

*TRANSMITTER MODULATED TRAIN DETECTION AND CAB SIGNAL FREQUENCIES

I I I I

'llECEIVEfl MODULATE!) I TRAIN DETECTION FllEOUENClES

TYPICAL VITAL RELAY RACK

I I I I I I I I I I I

-I

3870 HZ (F3)

2670 HZ (F21

RAIL

1 h!IO IIZ (r I)

fYl'ICAL TllACK CIRCUITS

T4

, F4


'1. CAB SIGNAL FREQUENCY = 990 HZ

2.TYPICAL TRAIN DETECTION FREQUENCIES:

F1=1590HZ· F2 =2670 HZ F3 =3870 HZ F4 =5190 HZ

3. TYPICAL SPEED COMMAND AND BERTHING CODE RA TES.

! =5.0 HZ C2 =6.6 HZ CJ =8.6 HZ C4 = 11J.8 HZ C5 = 13.6 HZ C6 = 16.8 HZ 81 = 20.4 HZ (BERTH) 82 ~ 27.5 HZ (BERTH)

1590 HZ (Fl)

RAIL

Figure 1-1. AF-400 Audio ~requ7ncy Train Detection and Cab S1gnal1ng

System, Typical Equipment Relationships

ix/x

UNION SWITCH & SIGNAL EB

SECTION I

GEKERAL INFORMATION

1.1 PURPOSE OF EQUIPMENT

The AF-400 Audio Frequency Train Detection and Cab Signaling System, hereinafter referred to as the AF-400 System (See Figure 1-1), continuously detects vehicle location within track circuit blocks and interlockings, and transmits speed command cab signals or other control information to the vehicles. Whereas train detection {block occupancy) occurs continuously, the transmission of cab signals is controlled by logic circuits external to the AF-400 System. The cab signal code rate to be transmitted is also determined by external logic circuits controlling vital relays and is based upon occupancy of other track circuits, civil speed restrictions, and other factors.

In addition to the essential functions of track occupancy and cab signaling, the AF-400 System, when properly applied and adjusted, is capable of detecting broken rails. Also, when the AF-400 System is applied such that an end of the AF track circuit is adjacent to insulated joints,' shorted insulated joints can be detected.

1.2 SCOPE OF OPERATION (See Figure 1-2.)

In the automatic territory that lies between interlockings, the jointless mainline rails are subdivided into a number of audio frequency (AF) detector track sections. In the modern rail transit signaling system, the length and location of these detector track sections are determined by the control limit diagrams which are established to provide the required headway and to take care of restricted speed zones. The AF-400 System achieves continuous vehicle detection with a single-ended, double-rail, AF track circuit. Insulated joints are not required except at interlockings or at locations where precise track circuit definition is needed. The track circuit is intended for use in de propulsion rail transit systems with either cam controlled or chopper-controlled vehicles.

The essential functions of track circuit occupancy and cab signaling are implemented by transmitter/receiver circuits contained on printed circuit boards (PCBs) housed in a cabinet card file in a central instrument house or equipment room. The card file, which occupies the full width of a 19-inch equipment cabinet, also contains a track circuit Coder/Oscillator PCB. The Coder/oscillator PCB generates one of four possible track circuit output frequencies, depending upon the particular track circuit being serviced, and supplies this signal to the transmitter circuit. In addition, the transmitter circuit also requires an externally-generated cab oscillator input

1-1

...... I

N

F4 __..,.

r------, I TUNING I I PANEL I '--------'

CODE RATE i\Ef

Tf1ACK CIIIClJIT OCCUPIED

I ncvn I IF41

TA4 - CAO ON/

.... 1----------TRACK CIRCUIT

---, : COUPLING : UNIT

-·

.--~---, I TUNING I PANEL I L, __ __ ..J

I

I CODE RATE

XMTH 11EF IF 11

j ~ I. en

~

" ncvn IF11

1/2 OF Ci FILE

TRI -arr CONT CAO OSC (990 UZI

' CODE RATE SELECT

BERTH CODE ENABLE •

.J

'

r I I

---, : COUPLING I llNIT

_J

TUNING PANEL

-, I I

L. - - - - - _J

I I CODE RATE I XMTR llEF

IF71

I I j ~ I.

cs

'1 1/7 OF CAfH) FltE

CODE RATE COOE

CAB SELECT RATE ON/OFF SELECT CONT LOGIC

24V ... CODE RATE CAB

-1':LJ SELECT TURN-ON LOGIC LOGIC

I I u CAB I --

TUnN·ON r--1 I I

LOGIC I I BEFHH!NG I I I

ETBSCT

TIMER I I I

I _,,,?-: '--- .J

I TRACK

....___~24v CIRCUIT OCCUPIED

BERTHING 24V~ APPLICATION

CONTACT

Figure 1-2. Typical AF-400 System, Simplified

... NORMAL DIRECTION OF TRAFFIC

---, F2 __. I COUPLING FJ.

: UNIT -

ncvn (F,I

------Tfl2

----CODE .... ..... RATE SELECT LOGIC

'---' FROM ROUTE SELECTION LOGIC

_.,

r-I TUNING I PANEL L __ --

-, I

CODE FlATE XMTR HEF -11'3}

j I I c~

-

cAn nsc -~~- (tl!>tltfl)

CODE RATE SELECT CAB

ON/OFF CONT

CAB TURN-ON LOGIC

I

TRACK CIRCUIT OCCUPIED

Block Diagram

I ,

EE c z i5 z ! =i 0 ::c flll (/)

G) z )> r

UNION SWITCH & SIGNAL EB frequency of 990 Hz and a code rate square wave input, representing commanded train speed (and/or berthing status), from a Coder/Oscillator PCB.

1.2.1 Track occupancy Detection Function

when the track circuit in question is not occupied, the 990 Hz cab oscillator input to the transmitter circuit is disabled, and only the train detection frequency is modulated by the code rate square wave inFut on alternate half-cycles. This signal is applied to the minibono coupling unit at the track circuit exit boundary via a tunitg panel. ~~e tuning panel, which is mounted at the back of the track circuit card file, occupies the full cabinet width of 19 inches, ano contains a single PCB that provides two independent coarse/fine selectable tuning circuits. With the tuning panel s~itches properly set up, the tuning circuit provides maximum transfer of track circuit signals by compensating for differences in cable capacitance between the equipment cabinet and the external rails. The coupling unit at the track circuit boundary is tuned to three frequencies; namely the cab signal frequency (990 Hz), the specific track circuit transmitter frequency, and/or the track circuit receiver frequency for the adjacent track circuit. The tiinsmitted track circuit frequency, therefore, is coupled from the transmitter to the minibond which, in turn, applies the signal to the rails.

Since the track circuit is unoccupied, the train detection frequency is picked up at its entrance boundary by a minibond-coupling unit, also tuLed to the same track circuit frequency (as well as the adjacent track circuit frequency). This track signal is coupled to the Receiver Input PCE in the sarne card file, via half of a tuning panel circuit. The receiver input signal is amplified, demodulated, and supplied tc the Receiver s:i,nchronous Rectifier PCB, together with a code rate reference from the Coder/Oscillator PCB. The received cede rate is s-ynchronously rectified and the resultant de output signal causes a vital track circuit relay to energize, thereby indicc.ting the track circuit is unoccupied.

I± a train enters the track circuit boundary, the transmitter signal is shunted by the train axle away from the entrance minibond-coupling unit. Therefore, the receiver input signal falls below its minimum o~erating threshold level and this causes the vital track circuit relay to deenergize and thereby indicate track circuit occupancy.

1.2.2 Cab SigLaling Function

~lien a train enters the track circuit, an external vital relay provides a cab enable to the Transmitter PCB. As a result, the cab signal of 990 Hz is now also modulated by the speed command code rate. Therefore, the transmitter outputs a composite signal, with the train detection frequency modulated by one half-cycle of the code rate, and the cab signal of 990 Hz modulated by the other halfcycle. The 990 Hz component of the signal is recognized by the cab

1-3


pick-up coils and is suppliec to the cab signaling control circuits for automatic train operation (ATO) and protection (ATP). The cab signal frequency of 990 Hz is generated by a separate PCB, usually housed in a 5-inch card file ,..-i th the Berthing Timer PCB; two or more of these Cab Oscillator ?CBs can be housed in the same 5-inch card file.

1.2.3 Cab Berthing Status Function

To indicate berthing status, the Berthing Timer PCB is used to provide an asymmetric multivibrator output waveform. The on time of the train berth signal is used to energize a vital train berth stick control track relay (TBSCT). wnen this relay is energized, its contacts enable the train berth speed command output of the Coder/oscillator PCB and enables cab signal transmission; when its contacts are deenergized, the Coder/Oscillator PCB outputs the proper speed command code rate. Therefore, the speed command code rate and train berth code rate are essentially time-division multiplexed over a total period of approximately 2.1 seconds, with the train berth code rate occupying about 0.7 second (the multivibrator on time). During the off period of the train berth multivibrator output, the speed command code rate continues to modulate the train detection (track frequency) and cab signals. ~he train berth timer circuit (there are two independent timer circuits on a single PCB) is enabled by contacts on a vital berthing application relay. This relay energizes when the train is within the station track circuit boundaries, and, the track circuits on either side of the station track circuit are unoccupied.

1.3 PHYSICAL DESCRIPTION

The AF-400 System equipment can be divided according to its physical location in a typical installation. The trackside equipment consists of a minibond and coupling unit which are bolted together to form an integral unit that is usually mounted to a tie between the rails.

The remainder of the system equipment is mounted on a 19-inch rack usually located in a central instrument house or an equipment room. All of the electronic circuits for the system are contained on modular PCBs: most of the PCBs for a track circuit are installed in a card file within the cabinet. certain auxiliary functions, such as the cab oscillator and berthing timer, are contained in smaller 5-inch wide card files within the cabinet. The transmitter portion of a particular track circuit requires three PCBs, while the receiver portion requires two PCBs. Therefore, one complete track circuit consists of a minimum of five PCBs. The 19-inch card file is capable of accommodating two complete track circuits, or 10 PCBs. (See Figure 1-3.)

The 19-inch card file is designed for mounting in a standard communications cabinet. A typical cabinet or rack configuration usually

1-4

!"':, AF TUNING PANEL I 11

~ I' I , I, 11

:.,--.. Ii , --~ · Ii : I., II i !' l : I , 1 1l

i1 Ii


PCB CONNECTOR

CODER/OSGI LLATOR

CARD FILE TERMINAL BOARD

AF TRACK CIRCUIT PCB LOCATIONS

Figure 1-3.

--RECEIVER SYNCHRONOUS RECTIFIER

POWER TRANSISTOR

CODER/OSCILLATOR

AF TRACK CIRCUIT PCB LOCATIONS

TRANSMITTER

Track Circuit Card Files Typical Ar=angement (Sheet and Tuning Panel, 1 of 2)

1-5

83 UNION SWITCH & SIGNAL

N451052-3401 (990 Hz, 1590 Hz, 2670 Hz) ,..., N451052-3402 {990 Hz, 2670 Hz, 3870 Hz) N451052-3403 (990 Hz, 3870 Hz, 5190 Hz) N451052-3404 (990 Hz, 5190 Hz, 1590 Hz) N451052-3405 (990 Hz, 1590 Hz, 2670 Hz)

Weight 18 pounds (8.0 kg)

Mini bond (Basic) N451003-0701 Mini bond (With Coupling Unit) :

Part No. Frequencies

N451002-0901 (990 Hz, 1590 Hz, 2670 Hz) N451003-0902 (990 Hz, 2670 Hz, 3870 Hz) N451003-0903 (990 Hz, 3870 Hz, 5190 Hz) N451003-0904 (990 Hz, 5190 Hz, 1590 Hz) N451003-1001 (990 Hz, 1590 Hz, 2670 Hz) N451003-1002 (990 Hz, 2670 Hz, 3870 Hz) N451003-1003 (990 Hz, 3870 Hz, 5190 Hz) N451003-1004 (990 Hz, 5190 Hz, 1590 Hz) N451003-l005 (990 Hz, 1590 Hz, 2670 Hz)

Weight 86 pounds (39 kg}

1.5.3 Track Circuit

Shunting Sensitivity Not less than 0.2 ohm resistive for a properly adjusted circuit

Maximum Track Circuit Length 1200 feet (366 meters) at 5 ohm minimum ac ballast resistance at operating carrier frequency

1-10


SECTION II

SYSTEM APPLICATION

2.1 INTRODUCTION

In order to operate as intended, the AF-400 System must be properly applied and adjusted. The following paragraphs describe application information based upon typical system diagrams. Because of the complexity of certain applications, particularly in and around interlockings, detailed application of the system is dependent upon specific requirements and drawings peculiar to the transit line under consideration. Section III, Installation and Adjustment, outlines the adjustment procedures required after the system is installed.

2.2 TYPICAL SYSTEM LAYOUT

As previously mentioned, the electronic circuits for the systems are contained on five PCBs that are housed in one-half of a 19-inch wide card file. Three of these boards make up the transmitter function and two boards perform the receiver function. A typical system layout is shown in Figure 2-1, which shows a single track circuit as applied in jointless mainline territory. Input/output connections to the card file are provided by two 34-pin connectors (TBl and TB2), with each connector se~vicing the electronic circuits for one track circuit {one complete 19-inch card file houses two track circuits or 10 PCBs). The card file connections are shown in Figure 2-1 as hexagons.

2.2.l Berthing Timer Application

Application of the Berthing Timer PCB is shown in Figure 2-2r this PCB is housed in a separate 5-inch card file. When the external berthing application relay is energized, 24 Vdc is applied over the berthing application contacts to the berthing timer PCB. To permit maximum flexibility in application, each PCB contains two completely independent timers, so that one board can handle two track circuits.

With de power applied, an asymmetric square wave drives a vital train berth stick c0ntrol track relay (TBSCT). When this relay is deenergized, the cab signal turn-on logic is connected to terminal 3 of the card file, as usual, and terminal 19 is connected to the external code rate select logic circuits. on the other hand, when the TBSCT relay is energized, the cab signal of 990 Hz is forced on by connecting terminal 3 of the card file to B24-T. At the same time, the code rate is forced to 20.4 Ez by a second contact which connects pin 2 of the Coder/oscillate~ PCB (terminal 19) to the 20.4 Hz code rate input at terminal 26. For applications that require two different berthing signals, additional external logic (not shown) is necessary to select between berthing rates of 20.4 Hz and 27.5 Hz.

2-1

~ UNION SWITCH & SIGNAL

2.2.2 Code Rate Reference Interconnection Between Locations

For normal receiver operation, the Receiver Synchronous Rectifier PCB requires a code rate reference output signal from the Coder/Oscillator PCB. As shown in Figures 2-1 and 2-2, this signal is obtained by jumpering terminals 15 and 16 on TBl and TB2 of the card file. Between each pair of equipment locations, there is one track circuit on each track for which the transmitter and receiver circuits are physically separated. In this case, it is necessary to send the Coder/Oscillator reference output signal over line wires to the Receiver Synchronous Rectifier PCB at the distant location. To obtain electrical isolation and noise immunity, a Line Transmitter/Receiver PCB is necessary at each end of the line wire circuit as shown in Figure 2-3. This PCB is also housed in a 5-inch card file and contains a line transmitter circuit and a line receiver circuit so that identical PCBs may be used at each location.

In Figure 2-3, the PCB in train control room Bis used only for transmitting. Two power supply connections are required, one to the oscillator power supply, and the other to a 15-20 Vdc line battery. The PCB in train control room A is used only for receiving and requires only the oscillator power supply. The line wire between train control rooms should be #14 to #22 AWG copper (depending upon application), and not more than 12,000 feet long.

2-2

)

)

-RBI 5 TO ADJACENT , r TRACK CIRCUIT RECEIVER -RN! 6

AT

I COUPLING SI .i~ UNIT CT

'--~--L't_1___, S2 2

MINIBON

N45 I OOJ-0701

1/2 OF TUNING PANEL a'., N45 I 522-8901

l I I I I

,-----------------------: I I I I I I

: RECEIVER I f SVNCflRONOUS I I RECTIFIER I I N4Sl570--2'901 - 1-5----@RF:LAY'

I ---~ I I I I __!.] 17 ~ RELAY

: st• I I s101 I I 14 1--le I I 30 N24-R I I

I ~824-R

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l 1 I 18 :

I RECEIVER I

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N451570-30XX I RX INPUTS

r

s' 'i I i I

6 I l---'--'IJ,__ __ _,,IJ2'\.-------~•,cR,c,.Ncl. ------~-~

I COUPLING UNIT

; !

~

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I 12 OF TUNING PANEL

N451522-8901

UNION SWITCH & SIGNAL

)

ijiNT80NO

) N"5 I OOJ-0101

., .

4

a:,

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H :I

: INPUT II @>----------~·~RB"-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 I

POWER TRANSISTORS

N45 I 054-9302 10

12

10

II

12

14 15

TRANSMITTER

N4S/ 570- I 9XX 16

I I I I I

TO B24T THRU CAB 1URN ON LOGIC

I f-'-'' ·~2---+---1----------------(,) 824-T

I I 7, I B

~f-!'IJ,c_ _____ _,_l~J

IRl..5-1 ~-I-R2-.1-, -114--9)· ~-R-J-LI_R_4_1 8 -' ____________ . -=~] I 2 N24·T

~l-9"---1---l---+-----------------Y,,' CAB OSCILLATOR 121111 ~-y INPUT ffi

2.s-~~~ ~ f:~s'~~~s I I

I I ~i~in~~i~i ~-.i>-; '"} +-------+----------------~! OUT

,------'-'1~7 __ J-'1~6j--?.2 ____ .j._ _______________ --{'!9 JUMPER

CODER I OSCILLATOR N451570-83XX

l-"3----·+------------------tzil> 5.0 Hl

l-'4----+------------------rt,)&.6 HZ f-"6----.J-------------------t;.2 8,6 HZ 1-"B----+------------------~~ 10.8 Hl

~Q-----1----------------------<~~~!3.6 HZ 12

f 125 16,8 HZ

~i~J f-!'14::._ ___ +------------------t',s 20.4 HZ L _____ J_~ __ j-"15'-----f------------------® UNUSED OR 27. 5 HZ

I I 8 I

'-------4---------------.....;[s) N24-0

I

I I I I I I '----------------------------------------------------------------~

112 OF CARD FILE

N451082-IDOI

< <

m~ a: a: <t <

TO ADJACtNT TRACK CIRCUIT

TRANSMITTER

WARNING:

THIS IS A VITAL SAFETY CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIR· CUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL

CAB OSCILLATOR N45!1)54-ll02 IS LOCATED IN A SFPARAIE M<JOULE, ONE CAB OSCILLATOR MAY URIVE UP TO 20 TRANSMI Jl[R BOARDS.

COUPLING UNITS PHYSICALLY MOUNTED TO MINIBOND

TUNING PAN[L l.lOUNTED TO BACK OF RACK BEHIND CARD FIL[

J. 0 - INOICAT[S CONNECTION TO TSI 10R 182 J ON CARO FIL£

4, STATION SYMBOL "X <Yl" -"X" INOICATES STATION FOR LEF"T HALF OF CARD FILE, "IYJ" JNOICATES STATION FOR RIGHT HALF, EACH HALF OF CARO rt LE IS WIRED IDENTICALLY,

D 451270-0201 REV 5

Typical AF-400 System Application Diagram for a Single

Track Circuit

Figure 2-1.

2-3/2-4

112 OF CARD F !LE

N45 I 082-1 001

,--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 I I

---------------------

POWER 4 6 TRANSISTORS

10 T N451054-9302

6 >O

7 II

12 12

~ 13 13

I

15 "--../ 14 9 "----../j B

Rl-<RZI R3-CR4 I , 5 OHMS 2,5 OHMS

N<5 I 003-0701

TO ADJACENT MINIAONO CT

PLATFORM

AT

~-----------------------1 I I I I I I

16 ... ... -· ~---4 4

I

~ I .... l-3 ". I I I I I

------ l ........ -__ 4_ I

-----·1 I t 12 or TUNING I I PANEL .·1' I I N4Sl522-8901 I I

I I

I~~ I CO z I ... ... I ''\ 54. I

--- ----------'

14 15

TRANSMITTER

16 N-151570-19)()(

1,2

IT, I 8

~ I 9

s j 3 6

17 16 2

CODER I OSCILLATOR 3 N'l5 I 5T0-83XX

4

6

e 10

I 2

r 14 I

15

' I 8

I I I

RECEIVER SYNCHRONOUS RECTIFIER

N451570-2901 l--'-"15 __ -r1·34 RELAY - (Al

?~. '' 1 ··· "

.L ' ·- ---- ·-

R(CE I vrn INPUT II

N451570-30XX 13

p, '

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r,9n [I A1 • (AI

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K"l> N

~·~II ?4 n

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. JI

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1 '2

I I I I I I I T 0 82.!lT THRU

I 3

I

c AB TURN ON LOGIC ------~~ B24-T

CAB TURN-ON

TBSCT

I B 24-T LOGIC I

I 2 N 24-T

I "®; I

AB OSCILLATOR NPlJT &.

I I 1s>~ I I I I

1'6 _I

CODE RATE REFERENCE

IN}

OUT TBSCT

19 IJM:lli-------...._.----O HZ 1~L~i~Elitw .,. __ J 120 s.

21 6.

@e,

-ITT> IO

@,1 ~16

6 HZ

6 HZ

. 0 HZ

. f. HZ

. 8 HZ ~.J:[z____ _________ _ @2.0

®"" I USED OR 27,5 HZ

I I B N2 4-0

I 17 62 4-0

: I I • I

'---------------------------------------------------------------- I

COUPLING UNIT

I /2 OF TUNING PANEL

N451822-8901

MINl8DND

N451003-0TOI

TO ADJACENT MINIBOND CT

TO CAB SIGNAL TRANSMl TTER

I OR 9

BERTHING TIMER

BERTHING APPL! CA Tl ON CONT ACT

~824-T

N451570-1802 ,e

3 OR II

TBS CT

ffi CAB OSCILLATOR N451054-1302 IS LOCATED IN A SEPARATE MODULE, OtJE CAB OSCILLATOR MAY DRIVE UP TO 20 TRANSMITTER BOARDS.

COUPLING UNITS PHYSICALLY MJUNTEO TO UINlBONO

TUNING PANEL MOUNTED TO BACK OF RACK BEHIND CARO F !LE

3. 0 - !NOICATES CONNECTION TO TBI !OR TB2> ON CARO FILE

4, STATJON SYM30L "X CY)" -"X" INDICATES STATION FOR LEFT HALr or CARD r ll[t "( y )" INDICATES STATtON FOR RIGHT HALT, EACH IIAtf or CARO f!L[ rs WIRED IDENTICALLY,


WARNING:

THIS IS A VITAL SAFETY CIRCUIT. ANY ClnCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIRCUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

D 451270-0202 REV 6

Figure 2-2. Typical AF-400 System Diagram for Berthing

Timer Application

2-5/2-6

SI Pl

ATR COUPLING CT UNIT

TO ADJACENT TRACK CIRCUIT TRANSMITTER

52 P2

MINIBOND

N451003-0701

"' z a:: a:: m m

3 4

BRBIA

112 OF TUNING BRNIA 2 PANEL

RX _______ INPUT

I /2 OF CARDFILE N451082-IOOI

(RECEIVER CARDS ONLY>

TRAIN CONTROL ROOM "A"

2 ~~PUT ------, I I I I I I I I I 15

lcooE IRATE l~~~UT I

024-0 N24-0

' /

I II

LI NE TRANS Ml TTER RECEIVER

· 14 N451570-3101 CODE OUT

ROOM A fWOM B

12 (BllHI OR 2HI

11 (B)ILO OR 2LO JLINE WIRES

FROM XMIT TCR 118 11

I I

I BTR I I I I

LINE WIRE{(A)IHI OR 2HI 8

TO REC, TCR 11 A11

(AllLO OR 2LO 9

DRAWING D451270 SIL 0203, REV, 0

CRBI 5 TO ADJACENT TRACK CIRCUIT RECEIVER CRNI

6

824-0 N24-0

SI Pl

co~th'NG CT

m z 0:: 0:: u u

3

I /2 OF PANEL

"" z 0:: u

52 P2

MINI BOND

N451003-0701

4

TUNING

2

4 5


CTR

,------

18

LINE TRANSMITTER RECEIVER

tJ451570-3101

3 16

LB LN

1 I I I I I I I

r 6'-----<.116 CODE IN CODE I

RATE I ~fi~ I

I I I I I I I

I /2 OF CARDFILE N451082-IOOI

(TRANSMITTER CARDS ONLY)

TRAIN CONTROL ROOM "B"

Figure 2-3. Typical AF-400 System Diagram for Line

Transmitter/Receiver Application

2-7/2-8

UNION SWITCH & SIGNAL EB

SECTION III

INSTALLJ.~TION AND ADJUSTMENT

3.1 INSTALLATION

In general, the electronic circuits making up the AF-400 System are contained in card files that are housed in equipment cabinets in a central instrument house or equipment room. Depending upon the length of track being serviced, a number of individual track circuits may be present as part of at overall train detection and automatic block subsystem. Therefore, installation of these track circuits depends upon the particular rail transit line drawings which specify the location and method of installation for these track circuits. Section II describes and illustrates typical applications of the AF-400 System.

3. 2 ADJUSTMENTS

Once the AF-400 System is installed in a particular track circuit environment, it must be properly adjusted for correct train detection and cab signaling levels. These adjustment procedures are performed on the PCBs and tuning panel making up the track circuit electronic circuits in the equipment room. Once these adjustments have been made, the overall system is tested to demonstrate that the track circuit is functionally operational and to provide a performance check of system operating parameters. During performance of the adjustment procedures, reference Figure 2-1.

3.2.l Recommended Test Equipment

The recommended test equipment required to adjust and test the AF-400 System is listed in Table 3-1.

QTY

1 1 1

1 1 3

Table 3-1. Recommended Test Equipment for System Adjustments and Tests

NOMENCLATURE MFR DESIGNATION

Oscilloscope Tektronix 465B or T912 Frequency/Period counter Hewlett Packard 5307A Digital Multimeter Fluke 8050A-01 or

8040A cab Signal Test.Set 0.2-0hm Shunt card Extenders US&S N398028

3-1


3.2.2 Adjustment Procedures

Ce1tain test ~oint~ ana co~trols on the Transmitter PCB are inaccessible unless the PCB is placec on an extender board. This is also true for the Receiv~r Synchronous Rectifier PCB. The procedures outlinec in the following paragraphs assume that these PCBs have been ~laced on extender boards fer adjustment purposes. After adjustments are complete, the PCBs must be reinstalled in the appropriate card file slot.

Bias setting is safety critical. Never place a track circuit in service unless the bias is adjusted.

3.2.2.l 'Iransmitter Bias Adjustment.

a. On 'I'ransmitter PCB, rotate CAB COARSE switch Sl and TRACK COAR.SE switch S2 to posi ticn l ( fully CW) .

b. On Coder/Oscillator PCB place TRACK/CAB switch (SWl) to TRACK (up) positicn.

c. Set digital multimeter to measure de volts and connect to TP13 (+) and TPlO (-). These points are also accessible on the extender boarc as terminals 5 (+) and 18 (-).

d. Adjust bias voltage with potentiometer R21. If track circuit is 850 feet or less, set bias to 1.0 ±0.lV; if longer than 850 feet, set to 2.0 +0.lV.

e. Place TRACK/CAB switch on Coder/Oscillator PCB in center position.

3. 2. 2. 2 Tuning Panel Adjustment. 'I'l1e tuning panel adjustment compensates for varying line capacitance of the cable between the equipmer1t room and the minibond. The combination of minibond, coupling unit, cable capacitance, and tuning panel form a circuit which is resonant at three frequencies - two detection frequencies and the cah signal frequency. For minibonds shared by two track circuits, i.e., jointless track circuits, the tuning panel adjustment is to be made at the highest frequency. At an insulated joint boundary, minibonds are not shared and tuning should be adjusted at the detection frequency of the particular track circuit. The tuning panel is mounted on the back of the equipment rack; access to the adjustment is obtained by rotating the quarter-turn fasteners and allowing the panel to swing o~en on its hinge.

3-2


HAZARDOUS VOLTJ..GES M.A .. Y EXIST ON THE TUNING PANEL AND ON TEE TERMINALS ON THE EXPOSED BACKPLANE OF TEE CARD FILE. CARE MU ST BE TAKEN TO AVOIL ELECTRICAL SHOCK. THIS ADJUSTMENT SHODLD BE PERFOR!vlED ONLY BY TRAINED r.'.LAINTEKANCE PERSONNEL.

a. Connect digital multimeter or oscilloscope across terminals 3 and 4 of TBl (or TB2). Note that each tuning panel consists of two independent sets of capacitors and switches. The appropriate terminal board must be determined for the track circuit being adjusted by reference to the code command application sheet. If highest frequency is being transmitted at this location, set associated Coder/oscillator PCB TRACK/CAB switch to TRACK position. If highest frequency is being received, then locate Coder/Oscillator PCB for transmitter end of track circuit and set its TRACK/CAB switch to TRACK position.

b. If transmitter output level has already been set, or is known to be approxizately correct, then skip to step c. Otherwise adjust Transmitter PCB for an initial output level by setting TRACK COhRSE switch to position 2 and TRACK FINE potentiometer to mic-range (about 7 turns from either end}.

c. Adjust tuning panel COARSE switch for maximum amplitude: then adjust FINE s~itch for maximum amplitude. It may be necessary to alter COARSE switch plus or minus one step when adjusting FINE control.

3.2.2.3 Receiver Synchronous Rectifier Adjustment.

a. Open speed selection logic from J connection of Coder/oscillator PCB by reo-sticking heel of first contact. (Refer to appropriate code command application circuit sheet.)

b. Generate a 16.8 Hz code rate by jumpering Coder/Oscillator PCB connector pin 2 to pin 12 (pin 19 to pin 25 on card file terminal board TBl or TB2, depending on half of card file being used).

c. Place TRACK/CAB switch on Coder/oscillator PCB in center position.

d. Set track signal on Transmitter PCB by adjusting TRACK COARSE switch to position 2 and setting TRACK FINE potentiometer to mid-range (approximately 7 turns from either end). Final adjustment will be made later.

3-3


e. Connect digital multimeter across TLl (+) and TL2 (-) on Receiver Synchronous Rectifier PCB and set it to de volts (20 volt scale).

f. Alternately adjust R23 and R25 on Receiver Synchronous Rectifier PCB to obtain a maximum de level on multimeter.

g. vary track signal level output from Transmitter PCB to obtain approximately 6.0 volts de, and trim R23 and R25 on Receiver Synchronous Rectifier PCB for maximum voltage.

3.2.2.4 Train Detection Signal Level Adjustment.

a. Set code rate to 5.0 Hz by jumpering pin 2 to pin 3 on Coder/Oscillator PCB with red stick in place at heel of first contact in speed selectiori logic.

b. Adjust output of Transmitter PCB, using TRACK COARSE switch and TRACK FINE potentiometer, to determine point at which track relay energizes.

c. Place TRACK/CAB switch on Coder/oscillator PCB to TRACK position. Output will be a continuous carrier to permit measurement.

d. Measure output of transmitter at TP8 and TP9 (yellow) using rms voltmeter (digital multimeter).

e. Adjust output of transmitter to 1.5 times the voltage measured in step d.

NOTE

This completes preliminary adjustment of the track circuit.

f. Verify shunting sensitivity of 0.2 ohm at both the receiver bond and transmit bond. This is accomplished by placing a 0.2-ohm shunt across the track at both locations and verifying the track relay deenergizes in both cases.

g. For end-fed, center-receive (EFCR) circuits, in addition to shunting sensitivity, check broken-down joint detection. Alternately connect a short (0.0-ohm shunt) across each insulated joint and note if either track circuit indicates occupancy. If neither circuit indicates occupancy first double check tuning and, if required, then reduce output of the transmitter of the EFCR circuit until broken-down joint detection is realized.

3.2.2.5 Cab Signal Level Adjustment. For jointless track circuits the intention of this procedure is to provide sufficient cab signal current at the pre-shunt point. For double direction running, a

3-4

UNION SWITCH & SIGNAL ffi transmitter is required to send a cab signal toward a train approaching from either direction, except at insulated joint locations. The transmitter is to be adjusted so there is sufficient entering end current for the longer of the two directions. The procedures for jointless track circuits and for those bounded by insulated joints are different. A further distinction is made for track circuits defining station platform liEits. in that the cab signal current must be greater for door opening.

a. Jointless track circuits:

(1) Place a 0.0-ohm shunt across the rails 10 feet in advance of the entering end bond.

(2) Set cab signal test set in position to measure rail current approximately midway between shunt and minibond.

(3) Use an extender board to gain access to adjustments on Transmitter PCB and jumper pins 16 and 1 to enable cab signal portion of transmitter. The transmitter to be adjusted is not the one connected to the bond closest to the shunt; it is the next one encountered in the direction of traffic.

(4) Adjust CAB COARSE switch and PCB CAB FINE potentiometer on PCB until cu=rent, as measured on cab signal test set, is 250 mA.

b. Track circuits bounded by insulated joints: Place a 0.0-ohm shunt across rails at minibond, and position cab signal test set to measure cab signal current approximately 10 feet closer toward the transmitting bond. As before, adjust cab signal current to 250 mA.

c. Track circuits defining station platform limits: Cab signal current must be set higher for the door commands to operate. Place a 0.0-ohm shunt across rails 100 feet beyond entering end of the station platform and adjust cab signal current to 1.0 ampere.

3.2.3 Reaords and Data

After a track circuit is adjusted and tested, it is recommended that data be taken and recorded. This data recording process serves as a reminder to make sure all the adjusting procedures were followed and the records will assist if troubleshooting is later required. There are two types of data sheets. One provides a means to record and trace pertinent information relative to train detection for a single track circuit (Figure 3-1). Cab signal and tuning panel adjustment on the other hand are more clearly traceable when related to specific minibonds rather than track circuits. For this reason information on the second data sheet (Figure 3-2) is oriented on a per-bond basis.

3-5

m, UNION SWITCH & SIGNAL

Measurements of the Coder/Oscillator PCB carrier frequency and output Vrms, the transmitter output, and the receiver input are to be made at a code frequency of 5 Hz wit~ the TRACK/CAB switch on the Coder/ oscillator PCB set to the TRACK position. A 5-Hz code is selected because these parameters increase with code frequency and a base code is necessary to insure data consistency. The TRACK/CAB switch must be put in the TRACK position so the signals are not on-off modulated; otherwise, therms measurements are meaningless.

Measurements of receiver output, the synchronously rectified voltage, and relay output must be made while the carrier is being modulated. For these measurements the TRACK/CAB switch must be in the center position and, again, a 5-Hz code is selected for data consistency.

3.3 MINIMUM PERFORMANCE TESTS

Immediately following the post-installation adjustments (and during scheduled maintenance intervals) the following train detection and cab signaling tests must be performed to verify the integrity of the AF-400 System track circuits. (Refer to recommended test equipment list in Table 3-1.)

3.3.1 Train Detection Test

3-6

a. Set up following conditions:

(1) Red stick in place in speed selection logic as outlined in paragraph 3.2.2.3, step a.

(2) Signal generatec at the highest code rate as in paragraph 3.2.2.3, step b.

b. Disable cab carrier signal by removing any jumper across pin 1 and pin 3 of TBl (or TB2) on Transmitter PCB.

c. Set TRACK/CAB switch on Coder/Oscillator PCB to center position.

d. Verify that proper track relay picks up.

e. With-0.2-ohm shunt, verify that track relay drops while shunting rails at:

(1) Receive end rail connections

(2) Transmit end rail connections

(3) Approximate mid-point of track circuit.

£. Set TRACK/CAB switch to TRACK position on Coder/Oscillator PCB.

UNION SWITCH & SIGNAL 6,(3

Roana Location

Track Circuit No. Code C6mmand Circuit Sh.

Detection Freouenc~ Len!:ith Sh.

LOCATIONS

Cardfile Transmitter Receiver

Rela':I

CHECK OFF

Shuntin!:i, ReceiYer End Transmit End

Broken Down I.J.

Qperates at each code

SETTINGS AND MEASURED DATA

Coder/oscillator

Carrier (TJ4) Freouenc~ Vrms@ 5 Hz

Transmitter

Switch Position S2 OutPut Vrms

Receiver

lnPut CTP4) Vrms OutPut CTP5) VPP

S':lnchronous Rectifier

Demodulated ·CTL1-TL2) Vdc Rela~ out <TP5) Ude

Attested: Date: -· ---------------------------------------- --------------

Figure 3-1. Sample AF Track Circuit Adjustment Records, Train Detection Data

3-7


Room Location

Bond Location or Identification

CouPlins Unit T~Pe 1590-2670 <Fl, F2)

2670-3870 CF2, F3)

3870-5190 CF3, F4>

5190-1590 CF4, Fl)

Tunins Panel

Location

Switch Settinss Course Fine

Tuned to Freauenc~

Cab Transmitter

Location

Bias Vdc

Switch Position (51)

OutPut Vrms

Cab current set to 250 ma , 1 amp

Code Freauencies

Noniinal 5.0 Actual

Attested!

6.6 10.a 13.6 16.8

Date:

Elate:

20.4

Figure 3-2. Sample AF Track Circuit Adjustment Records, Cab Signal and Tuning Panel Data

3-8

27.S

UNION SWITCH & SIGNAL 83 g. At Coder/osc llator PCB output, verify steady-state train de

tection carr er frequency with frequency counter and record measured value. Tr,is signal is available across TJ4 and TJ3 of PCB.

h. Set TRACK/CAB switcn to center position.

3.3.2 Cab Signaling Test

a. Red stick in speed selection logic as outlined in paragraph 3.2.2.3, step a.

NOTE

If transmittiug cab signal to two blocks, first test in block used for adjusting.

b. Set signal to be generated at 16.8 Hz code rate as outlined in paragraph 3.2.2.3, step b.

c. Connect 0.2-ohm shunt across rails at entering end of block.

d. Approximately two feet in advance of shunt, place cab signal test set receiver coils across track.

e. Enable cab carrier signal as outlined in paragraph 3.2.2.3, step d.

f. Set TRACK/CAB switch on Coder/Oscillator PCB to CAB position.

g. Monitor cab signal carrier frequency across TP4 and TPlO on Transmitter PCB with frequency counter. Record measured value.

h. Set TRACK/CAB switch to center position.

i. Measure rail current with cab signal test set and monitor Transmitter PCB output with oscilloscope at 16.8 Hz code rate. Record rail current.

j. Repeat step i. with cab signal test set approximately two feet in advance of track shunt at:

(1) Approximate mid-point of block

(2) Exiting end of block

(3) Each turnout extremity.

k. Remove track shunt and cab signal test set from rails.

l. If transmitting cat signal to a second block, repeat steps a. through e. and h. through k. along that block.

3-9


3-10

m. Disable cab carrier signal as outlined in paragraph 3.3.1, step b~

n. Remove Coder/oscillator PCB jumper.

o. Remove red stick fro~ heel of first contact in speed selection logic.

p. Remove Transmitter and Receiver Synchronous Rectifier PCBs from card extenders, and reinstall PCBs in card file.

q. Monitor transmitter output on oscilloscope across TP8 and TP9 of Transmitter PCB. Verify absence of cab carrier signal in waveform display on scope.

UNION SWITCH & SIGNAL m SECTION IV

FUNCTIONAL DESCRIPTION

4.1 INTRODUCTION

This section presents a functional description of the AF-400 System and is divided into two parts. The first part discusses the functions of the System on a simplified block and functional diagram level. The second part of this section provides detailed circuit descriptions of the PCEs making up the system and are referenced to PCB schematic diagrams.

4.2 FUNCTIONAL BLOCK DIAGRAM DESCRIPTION

The major functions of the AF-400 System are twofold; namely, train detection and the transmission of cab signal information. The ancillary subfunctions of train detection are also discussed and include broken rail detection, broken-down insulated joint detection, and immunity to interference. Train berthed indication is described as a subfunction of cab signal transmission.

4.2.l Train Detection Function (See Figures 4-1 and 2-1.)

Figure 4-1 illustrates a simplified functional application of the AF-400 System. Transmitter Tl is transmitting a coded carrier frequency Fl to receiver Rl. Similarly, transmitter T2 is transmitting a coded carrier frequency F2 to receiver R2. Receiver R4 is receiving frequency F4 from an unseen transmitter to the left, and transmitter T3 is sending coded carrier frequency F3 to an unseen receiver on the right. (Refer to paragraph 1.5.1 for train detection carrier frequencies.)

The code applied in each track circuit block is the same as that which would be selected if a cab signal were being transmitted. This code usually depends on traffic conditions and civil restrictions, and the code rate is selected by vital relay logic which is external to the electronic equipment card file. When a vehicle is present in a block as shown in Figure 4-1, its axles shunt current away from the receiver in that track circuit. As a result, the vital track relay (in this case TR2) drops from its normally energized state. The vehicle is thus detected as being within the block (track circuit TC).

Without insulated joints at the track circuit boundaries, the track circuit shunts a short distance before the lead axle actually crosses the minibond rail connection location; this is referred to as preshunt distance. Similarly, as the train leaves the block, the track circuit remains shunted until the trailing axle has passed a short distance beyond the minibond rail connections; this distance is called

4-1

.i::-1

N

MB1

I F4 I

F1

~ PR

~ I

--

TA TB

)~ or C.I\IIDrl LE

-F---- + --~---, r-- ----- ----, I • I I __ __.___ I

R4 I I Tl R1 I I I I I I I

---1----J L--------- __ _J

I TR4 I cs I TR1 I LEGEND:

T - TRANSMITTER R - RECEIVER F - FREQUENCY TR - TRACK RELAY MB - MINIBOND/COUPLING UNIT PR - PROPULSION RETURN ICROSSBOND) cs - CODE RATE SELECTION LINES

NORMAL ( DIRECTION

MB2 / I OF TRAFFIC MB3

I F2 I ~ PR

I _L --

TC

,-- -------- ---, I I I I T2 R2 I I I I I L __ -------- --~

cs ~

n ~1 I

TD

r--:r---• I

I I I I

TJ

L ______ _

cs

Figure 4-1. AF-400 System, Simplified Functional Block Diagram

EE c z 0 z

' ~ 0 J: Qfl (/)

i5 z )> r-

UNION SWITCH & SIGNAL ffi the post-shunt distance. TLe actual pre-shunt and post-shunt distances are dependent on ballast resistance, frequency, and equipment design. The AF-400 System is designed to control these distances to permit close headway operation normal to modern transit environment, while satisfying all other functional requirements. Pre-shunt and postshunt distances of 40 feet or less are typical for the AF-400 System.

4.2.1.1 Broken Rail Detection Subfunction. Broken rail detection is dependent largely on proper application of the AF-400 System and on the design of the external propulsion power return system. Broken rail detection can be obtained provided the following conditions are met:

a. Each AF-400 System track circuit must be properly installed and adjusted.

b. Parallel tracks may not be cross-bonded more frequently than every other track circuit. Regardless of the number of intervening track circuits, cross-bonding may not occur at less than 1400-foot intervals.

c. Any auxiliary equipment that operates from the propulsion power supply (third rail), such as switch heaters, third rail heaters, pumps, etc., must have the negative return connected to the centertap cf the nearest minibond, not to a running rail.

4.2.1.2 Broken-Down Insulated Joint Detection Subfunction. Detection of broken-down insulated joints is accomplished by the proper applica:ion cf the three-frequency coupling units on either side of the insulated joint. In continuous rail territory, the minibond-coupling unit must be tuned to three frequencies; namely, the cab signal, transmitted train detection signal, and received train detection signal. Thus, at an insulated joint, the coupling units on each side may tune to common train detection frequencies. In the event a joint deteriorates or shorts, each minibond appears as a high impedance to the other, which makes detection of the failed joint difficult.

Since different train detection frequencies must be used in adjacent track circuits, the rninibonds on each side of the insulated joints should not be tuned to any common train detection frequencies. When this is the case, a broken-down insulated joint causes each minibond to appear as a shunt to its opposite number. Therefore, one (or both) track circuit receiver is denied adequate signal strength, resulting in detection of the joint failure. In order for detection to occur, the combined (vector sum) impedance of the failed joint and of the cable connecting the minibond centertaps must be less than 0.05 ohm. This is the equivalent of 0.2 ohm across the full bond winding (track side).

4.2.1.3 Interference ImmuLity Subfunction. Noise immunity is intrinsic in the design of the AF-400 System, making it immune to the electrical noise which is characteristic of a rail transit system. These

4-3

EEJ UNION SWITCH & SIGNAL

noise sources include 60 Hz power harmonics, ripple from propulsion power rectifiers, and noise generated by vehicle propulsion choppers.

The receiver circuits, in particular, achieve high noise immunity by using very selective, narrow band-?ass filters to separate valid track signals from noise, and synchronous rectification of the recovered code rate. In the Receiver Synchronous _Rectifier PCB circuit, a code rate reference signal is needed from the Coder/Oscillator PCB. In almost all track circuits, the receiver and transmitter circuit PCBs are housed in a common card file, so that the code rate reference is readily available to the receiver. However, between equipment rooms {or central instrument houses) there is always one track circuit per track in which the transmitter and receiver are physically separated. In this case, a transmission wire pair must be used to carry the code rate reference signal from the transmitter location to the receiver location. { See Figure 2-3.)

To provide noise-free transmission and reception of the reference signal, a Line Transmitter/Receiver PCB is used. This board contains independent circuits that isolate the room and field wiring, and also suppress transients and other noise which may be coupled into the field wires. The Line Transmitter/Receiver PCB is housed in a 5-inch wide card file (sometimes with the berthing timer and cab oscillator PCBs).

4.2.2 Cab Signal Transmission Function {See Figure 2-2.)

The cab signal is generated by the Cab Oscillator PCB and consists of a 990 Hz sine wave; this signal is applied to the Transmitter PCB. The cab signal PCB is normally housed in a 5-inch card file with the Berthing Timer and Line Transmitter/Receiver PCBs.

4.2.2.l cab On-Off Enable and Speed Command. The cab input signal to the Transmitter PCB is transmitted, together with the train detection oscillator frequency, at an externally specified code rate representing a speed command. ( Refer to Paragraph 1. 5 •. 1.) The speed command is selected by vital relay logic (usually part of an automatic block subsystem) which connects pin 2 of the Coder/Oscillator PCB to a specific code rate input enable line. Up to eight code rates are available for cab signals. A typical application may assign one code rate for signaling the vehicle to switch to yard mode; four or five code rates for actual speed commands; and one or two code rates to signal that the train ia.properly berthed at the station platform to allow the doors to open.

In order to transmit a 990 Hz cab signal, a vital relay, separate from the speed command selection vital relays, is necessary to enable transmission. This signal is 24 Vdc and is usually referred to as the cab on-off enable; the vital relay contact closure for the cab signal enaLle normally occurs when the track circuit is occupied. The transmitted signal format is such that the train detection carrier and cab signal carrier frequencies occupy alternate half-cycles of the code

4-4

UNION SWITCH & SIGNAL ffi rate square wave as sho~n iL Figure 4-2. Although the two signals are shown as having equal amplitudes, the amplitude of each carrier frequency is indepeDdently a6Justable on the Transmitter PCB.

4.2.2.2 Train Berthed Signal Transmission Subfunction. An indication that the train is properly ~erthed in a station is obtained by use of a Berthing Timer PCB and a vital relay. (See. Figure 2-2.) The Berthing Timer PCB is housed in a 5-inch card file (usually with the Cab Oscillator and Line Transmitter/Receiver PCBs) and contains two independent berthing timer circ1...its. This permits one PCB to service both tracks in double-track territory.

~he Berthing Timer PCB generates an asymmetric square wave signal which, in turn, drives a vital relay (PN-150B). When the relay is deenergized, the speed comman~ code rate is selected over its back contact; when the relay picks, a train berthed code rate is selected over its tront contact. This per~its the speed command and berthing code rates to be time-division multiplexed as shown in Figure 4-3. This figure shows the s~eed command code rate alternating with a train berthed code over a period cf about 2.1 seconds. On board the vehicle, the automatic train protection (ATP) equipment decodes the transmitted signal. Since neither code rate is present continuously, the decoding filters are designed to bridge the gaps so that the signals appear to be received continuously. Only the three lowest code rates are used as speed comn:.ands while the train berthed indication code rate is being sent; this avoids penalizing the response of the higher frequency decocing filters which normally correspond to higher permitted speeds.

4.3 CIRCUIT DESCRIPTIONS

The following subparagraphs Lresent detailed circuit descriptions and are referenced to PCB logic ;chematic diagrams. Intimate knowledge of their operation is essential for maintenance personnel to fully understand, troubleshoot anc maintain the AF-400 both at the system level and during PCB shop rrcintenance. In addition, descriptions are also provided for the tunins panel PCB, coupling unit, and minibond.

4.3.l cab oscillator PCB (See Figure 4-4.)

The Cab Oscillator PCB generates the carrier frequency for cab signaling (~90 Hz). ~1e oscillatcr output is a 0.73 Vrms sine wave. Input power of 24 Vdc at 0.01 ampere is required.

The carrier oscillator emplcys a conventional Colpitts circuit with frequency determined by adjLlstable inductor Ll and capacitors C2, C3, and C4. The LC ratio of this tuned circuit, as well as the feed-back ratio determined by C2, C3, and C4, ensure excellent frequency stability and wave form. A therListor across a portion of emitter resistance R4 compensates for teLperature effects on the Q of the tuned circuit; therefore, the out~ut level is constant with temperature

4-5


CAB

SPEED COMMAND CODE RATE

TRAIN DETECTION SIGNAL

SIGNAL (990 HZ) (ENABLED)

COMPOSITE SIGNAL

Figure 4-2.

BERTHING TIMER OUTPUT

SPEED CMD AND TRAIN BERTH CODE RATES

FUNCTION

CAB SIGNAL (990 HZ)

r( 1.4 SEC

~SPEEDCMD

Transmitter Output Signal Format

*.7S~C* 1.4 SEC *.7SE~

I I

BERTHED BERTHED

* * SPEED CMD * )i

Figure 4-3. Time-Division Multiplexing of Speed Command and Train Berthed Code Rates

4-6

l

c, 22 µF

R1 11K

R2 18K

C2 C II.FD.

C3

µ!

RS 3K

R6 3K

200:: RS

02 PN 3643-5

10K R9

UNION SW!TCH & SIGNAL Efj

(Rl TP2

Y. AMP. 624(+)

F1

03 2N2270

20on R11

BOUTPUT

TP1 (YELl

.___--4._ __ --41,-_-..... _-----------411---+ 17 & 18 COMMON

TP3 (BP.fl..)

Figure 4-4. Cab Oscillator PCB, Schematic Diagram

changes. Resistor R4 also sets the output amplitude to the specified value. Emitter followers Q2 and Q3 serve to isolate the oscillator from the circuitry that it must drive. Capacitor Cl and resistor RB provide decoupling from the power supply.

4.3.2 Coder/Oscillator PCB {See Figures 4-5, 4-9, and 4-10.)

The Coder/Oscillator PCB provides two outputs: one is a 50-50 square wave to control the cab signal transmission, and the other, which is 180 degrees out of phase with the first, consists of bursts of track circuit carrier frequency which may be of 50-50 duty cycle or may be less, depending on the requirements. These bursts of carrier are of 50-50 duty cycle for the lower code rates and become of shorter duration for the higher code rates, with time being removed from the trailing edge of the on period. In addition, amplitude is raised as code frequencies are increased, in a proportion which has been determined by system tests. The code rate generator circuit consists of a dual unijunction transistor (UJT) oscillator to enhance safe operation.

4.3.2.l Block Diagram Description. (See Figure 4-5.) As shown in Figure 4-5, the track circuit carrier oscillator in the left-hand block is designed to be safe against any failure that may cause an increase in amplitude. The oscillator is followed by a unity-gain amplifier to provide a stiff voltage source at this carrier frequency. Output of this amplifier goes, among other places, to terminal 2 on the board. This pin goes out to external contact logic which provides

4-7

~ I

(X)

FAIL-SAFE CARRIER OSCILLATOR

27.5

T4 SECONDARY

fiiecmTER'sJ

L _J

Figure 4-5.

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MAST En U.IT

BOOST

SUM

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SI.AVE U.IT

ru1.sE COINC.

rur. FLOP

50-50 SQUARE WAVE

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-l SWITCH

rnonnAM-MAlllf I ... ( llMHl

IOIOOE --, I ORGATE I

L _ _J

PIN 17

Coder/Oscillator PCB, Simplified Block Diagram

EE c z 0 z I :::j 0 ::c Ai' CII

ci z )> r

UNION SWITCH & SIGNAL ffi a connection between it and any one of the eight taps on the transforme:r shown, with the top tap representing the lowest code rate and the bottom tap representing the highest code rate. Voltage across the w~ole transformer, therefore, increases as higher codes are selected. This voltage is rectified and used to power the charging circuits of each o± two complementary t.:.nijunction oscillators. The base su:;:,ply voltages for these two oscillators, which must remain constant as code rate is varied, come from two separate rectifiers on the amplifier output. This arrangement ensures that no single failure in these three power supplies can cause both oscillators to increase in frequency simultaneously. Failures in the base supplies, which could increase: frequency, would be expected to occur only one at a time in one base supply or the other. Because the voltage for the charging circuit of the u1,i junction oscillators is increased as taps further down on the transformer are selected, the frequency will be higher on these taps. V1is is the means used to obtain the various code rate frequencies. This method of frequency control provides a high degree 01 imTuunity against frequency increases caused by leakage from terminal-to-terminal in the frequency selection logic.

one of the two unijunction oscillators is designated as a master oscillator; it provides a small sync signal to the slave unit. If the slave: was already tending tc oscillate at a frequency close to the master, then the slave will be locked in by the master, and the two UJTs will fire simultaneously. The pulse outputs of these two UJTs feed into a pulse coincidence circuit which delivers an output only if its two ir1coming pulses coincide with one another. The resultant pulse operates a flip-flop which divides by two and provides a square wave at the coae frequency. Any drift due to failure within either the master or the slave unijunction oscillator, which causes its frequency to deviate more than a se:lected amount from the proper frequency, results in the two oscillators failing to be locked to one another. In that case their pulses do not coincide and there is no operation of the flip-flop. This means is used to provide safety against ariy failure within either UJT oscillator circuit which might cause its frequency to unsafely increase. Output from this flip-flop is one of U,e outputs of the board and is used to control the cab s ignaling gate on the transmitter board. output of the flip-flop is also aiiferentiated anct us~d to trigger a programmable timer whose operation is explained after the source for some of its control signals is describea.

system tests have inoicatea that it was necessary at the two lower track occupancy carrier frequencies and two higher code rates to relliove a certain amount from the trailing edge of the track occupancy carrier-on period, with a large amount being removed at the higher code (l6.8 Hz). Ther€fore, a control signal is obtained from these two code positions on the transformer to control the on time of the timer to times which are shorter than 50% of the code period by the desired amounts for each of the code rates. These two control signals are also ORed together through diodes to control the switch at the timer output. If either oi these control signals are present this switch gives preference to the timer. If they are not the switch is disabled and the output of the flip-flop is passed to the output

4-9


switch, thus allowing 50-50 duty cycle for those code rates which are not specially programmed to be of different durations. The last gate in this chain, then, is switched on and off at a 50-50 rate or at a lesser duty cycle for the higher code rates, and this switch is the one that modulates the train detection carrier frequency applied to the Transmitter PCB. It is now necessary to return to the source of this carrier signal to show how the required variation with code rate is obtained.

The voltage across the code selection transformer varies in approximate proportion to the code rate. A small amount of this varying voltage is obtained by the secondary winding on the transformer and is added to the constant carrier voltage output of the carrier amplifier. This provides a voltage variation with code rate which is approximately what is needed, but not quite. Systems tests show the requirement for a further, sharper increase in voltage at the two highest code rates. Therefore, an additional circuit, which is simply labelled "boost" in this block diagram, derives a carrier voltage only at these two highest code rates and adds it to that already obtained from the transformer winding. The total of all of these voltages results in the required rising characteristics with the code rate. This is the signal which is gated on and off at code rate by the last switch on the right; this modulated train detection frequency is passed on to the Transmitter PCB.

4.3.2.2 Circuit Description. (See Figures 4-9 and 4-10.) Schematic diagram Figure 4-9 depicts the circuit requirements for the two lower train detection frequencies of 1590 Hz and 2670 Hz, while Figure 4-10 shows the circuit requirements for the two higher train detection frequencies of 3870 Hz and 5190 Hz. Note that for the two higher train detection frequencies the signal boost and foreshortening requirements for the two higher code rates (13.6 Hz and 16.8 Hz) are not required, yielding a 50-50 modulation output for all selected code rates. The following circuit description applies to Figure 4-9 for the two lower train detection frequencies; the differences between the circuit configurations are easily recognized.

In Figure 4-9, the train detection oscillator circuit is associated with transistor Ql. output level of the oscillator is dependent upon its de power supply, which is determined by Zener diode Dl. The circuit is arranged to include the dynamic Zener impedance of Dl in the feedback path from the tap in the Colpitts capacitive divider at the junction of Cl and C4 to the emitter return for the transistor. Thus, if Zener diode Dl were to open and allow increased power supply to the oscillator circuit, the impedance that the emitter sees would be high enough such that no oscillations would take place. This ensures safety against any oscillation level rise. output from the collector of Ql is current amplified by Q3 through Q5 to provide a stiff source at the same voltage. Additionally, the de level at the collector of Ql, which is determined by R3 and R9, is coupled through to the output of the amplifier. This de level is used for purposes described later.

4-10

UNION SWITCH & SIGNAL EE Output from the amplifier ca~ be seen to go to the two independently derived power supplies for tr.e two unijunction oscillators; these supplies are labeled -Vee A and B. The amplifier output is also coupled through capacitor CS to :E,in 2 of the circuit board, which is the connection to the external code selection logic. The code selection contact logic supplies a connection between terminal 2 and any of the terminals (3, 4, etc.) which apply ac train detection frequency voltage to various taps on transformer T4. The output of transformer T4 is rectified by D8 and D9 to provide the variable charging voltage for the unijunction oscillators Q6 and Q7. The master oscillator Q6 dellvers approximately 10% of its pulse output through transformer Tl to base 2 of Q7. The polarity is such that this is a positive-going pulse, since capacitor C9 is charging to a negative voltage. A positive move at base 2 brings the unijunction close to firing. If the match between the charging rates of C8 and C9 is sufficiently close, this small positive move of C7's base 2 results in Q7 firing at the same instant that Q6 fires to produce the pulse. The circuit constants are chosen to allow this locking in to occur over an approximate 10% variation of the time constant of one of the charging circuits. The output pulses of the two unijunction oscillators, which are negative-going, are fed to the bases of transistors Q8 and Q9; Q8 is normally conducting and holding saturable transformer T2 in a saturated condition. If a negative pulse appears at the base of Q8, it removes the core of T2 from saturation and, if at the same time, another negative-going pulse appears to turn on Q9, the core is saturated momentarily in the opposite direction, producing a pulse on the third winding of T2. If these two pulses do not occur simultaneously, either one by itself can bring the core out of saturation but will not reverse its flux and saturate it in the opposite direction; thus, there can be no appreciable output from the third winding. This en-sures that there is no pulse to drive the following circuitry unless the two UJT oscillators are locked to one another. They cannot be locked to one another unless they would tend to otherwise agree in frequency to within a small error. Thus, any failure which makes either UJT want to wander appreciably in frequency, causes a loss of output that is detectable. 'I'r,is ensures the safety of the combined UJTs against any failure which would cause the pulse rate to change a~preciably; that is, to change enough to move to another recognizable code rate.

The positive pulse output from the secondary of T2 (X) is fed to the first half of dual flip-flop ICl which serves only as a threshold and waveshaping device. From this half it is fed to the second half of ICl which is used as a divide-by-two to produce a square wave at the desired code frequency. This square wave is delivered to the output through buffer Ql2 to output terminal 16 and, from there, is used to drive the respective gates in the Receiver Synchronous Rectifier and Transmitter PCBs. It is also differentiated by the Cl2/R34 combination and is used to drive programmable timer IC2.

Earlier in this circuit description it was pointed out that a certain de level had been provided at the output of carrier amplifier Q4 and QS. When code selection logic has connected pin 2 to any of the code

4-11


rate select terminals 3 through 8, this de voltage is simply shunted to ground through the low de impedance of transformer T4 relative to the high de resistance of Rl3. However, in the higher code rate positions, such ~s connector pin lQ, there is an additional higher resistance R47 in series with the lead of the transformer that allows a large portion of the de level coming out of the carrier amplifier to appear at pin 10. This carrier frequency component of the signal is filtered by R41 and C26 and the de is applied as a gating signal to switch IC3-13. Application of this input causes a connection to be made between its two output pins, in this example, pins 1 and 2. This establishes a connection between R35 and R36 and Cl3 which determines the duration of the timer output. Since board pin 10 is energized, then a signal through diode D3 is also applied to pin 12 of switch IC3. With this switch enabled, the output of the timer is connected to that of flip-flop ICl-1. Because the flip-flop has a higher resistance R32 in series with its output, action of this particular switch results in the eventual output being under control of the timer rather than of the flip-flop. Whichever of these two res is in control provides an output to remaining switch IC3-6. This switch enables the modulated track occupancy carrier signal to the Transmitter PCB, by way of PCB pin 17.

To obtain a track signal carrier which varies in the required manner with the code rate several sources are combined. First a safely regulated voltage at carrier frequency is obtained at the secondary connection of transformer T4, which is smaller and is proportioned to give the small rising characteristic which is required. Thus, the voltage applied to resistor P38 rises by 15 or 20% over the code rate range of 5.0 to 16.8 Hz on the board which is used for 1590 Hz carrier frequency. To obtain the additional rise required for the highest 2 track code rates, transistor Qll is arranged as a grounded base amplifier with its base referenced to one of the derived power supplies of constant magnitude for the UJT oscillator base supply. Its emitter is driven from the 10.8 Hz code rate select tap on transformer T4, which provides a voltage of such magnitude which, when referenced by C24 and Dl2, is enough to bring Qll into conduction for partial cycles only when the code selection logic has selected a higher code rate of 13.6 or 16.8 Hz. For lower code rates, Qll is non-conducting. These two sources of carrier energy are combined through R58 and R62 into the primary of tuned transformer T3. This transformer serves as a load which is guaranteed against increasing in impedance, and the output of its secondary-winding is the train detection signal which is modulated by code switching circuit-IC3-9 and sent to the transmitter PCB. Divider R63 and 64 provide the de level required by the transmitter PCB.

4.3.2.3 Coder/Oscillator PCB Safety Considerations. Any failure that occurs, will not cause the carrier level to increase. The circuit design associated with transistors Ql through Q5, as previously explained, ensures against any increase of carrier due to failure in this area. In addition, any =ailure should not result in the carrier shifting to a higher carrier channel frequency. The frequency is safe against any drastic increaseE, because the tuning capacitors are each made up of single capacitors rather than multiple capacitors in shunt,

4-12

ra UNION SWITCH & SIGNAL \JJ

and construction of pot core Ll ensures against any gross change of inductance. Frequency safety of such oscillators is well established by previous usage.

The selected code rate cannot increase to any other higher code rate due to failure. This requirement has been achieved by the previously described dual UJT oscillator circuits to a greater extent than in any code rate generator previously designed. Failures due to leakage in the external contact logic for code selection or due to failures in the frequency-determining portions of the UJT oscillators are both well guarded against. From the previous explanation of the circuits with regard to external leakage in the logic wiring, the signal used which passes through the logic contacts is ac rather than de, and there is thus no leakage that can increase its magnitude. If this signal is connected to any one terminal of transformer T4 to select a particular code rate, leakage of any sort to any other terminal has almost no effect in either direction on the code r~~e, because of the low impedance source provided to the intended connection. Leakage of this signal, in turn, to other boards in the system will not cause an unsafe effect because the carrier signal at this point is an unmodulated signal having no code information on it. Safety of the code generating circuits, as previously explained, is dependent on using two such circuits which are locked to one another only over a narrow range of changes in value in either circuit, followed by a circuit which checks the coincidence of the two UJT oscillators.

The period of the programmable timer output control is inherently safe, since it has been selected to be a magnitude which results in the greatest sensitivity of the receiver. Any failure in either direction in the duration-determining portion of the timer can only result in a receiver which will shunt more easily rather than less easily. Switch Swl is provided which, in one position, enables the track occupancy carrier continuously and, in the other position, enables the cab control signal to the transmitter board continuously. These two positions are used for checking amplitudes in the transmitter output and during track circuit adjustments.

4.3.3 Transmitter and Power Transistor PCBs (See Figure 4-11.)

The Transmitter PCB accepts one or two carrier signals and a code rate signal. Its output is a modulated and amplified signal which is normally applied to the rails. The basic transmitter (-1902) generates only a cab signal. The other transmitters (-1903 and up) generate a train detection signal as well as a cab signal.

The cab and wayside input circuits are similar. Treating the cab channel, a sine wave carrier signal from an oscillator board (N451054-1302) is applied to pin 9. The carrier signal is a 2 Vp-p sine wave superimposed on a 13 Vdc bias. Transistor Ql buffers the carrier signal. Resistors P2 and R3 divide the de bias to about 3V, but C3 bypasses the ac carrier signal so that it is not diminished~ Transistor Q2 and associated components perform both modulation and amplification of the carrier signal. Assume for the moment Q3 is

4-13


switched on and is fully conducting. Then the ac impedance of both Q3 and Dl are negligible, and the gain of Q2 is determined by the ratio of its collector impedance to the sum of R4 and RS.

The gain of Q2 can be varied in steps by selecting taps on transformer Tl with switch Sl. Between steps, RS provides a smooth change in gain. Thus, Sl and RS are used to set the cab signal output level to the track. Transformer Tl is designed so that the switch-selected ranges have a small overlap at each end of the adjustment range of RS. In addition, Tl and CS form a resonant circuit so that gain only occurs at 990 Hz, the cab signal frequency. The operation of the train detection channel is partly analogous to the cab channel; T2 and C6 are tuned to the train detection frequency, and Rll and Rl2 are tabulated to ensure the proper adjustment range for each of the four train detection frequencies. The difference from the cab channel is that the input to pin 3, c is already coded to allow variable on-time. The magnitude of the signal is 0.5 volt, superimposed on 5.0 volts of de. Because this de is different from that of the cab channel, RlO is of a different value to provide proper bias for QS. Since the incoming signal is normally already coded, Q6 performs a redundant function useful when testing the board.

The above description is true when Q3 (or Q6) is conducting. If Q3 is not conducting, then diode Dl is reverse-biased by resistor R7. The effective emitter resistance is very high, so that the gain of Q2 is reduced to zero. Note also that Q3 and Q6 are always in opposite states, so that only one signal, either cab or train detection, is transmitted at any given time. By applying a square wave voltage to pin 8, Q3 is forced to switch on and off, and Q6 switches with 180 degree phase difference. The result is that the cab signal is transmitted in alternate bursts. (See Figure 4-2.) The advantage of this arrangement is that the cab and train detection signals are modulated at exactly the same frequency, with independent level adjustment for each, and yet the overall amplifier size can remain small. In addition, since at any instant only one of the two signals is present, the output·power amplifier is time-shared between the two signals.

Transistors Q7 and QB perform a double function; Q7 is driven by the modulated cab signal and Q8 by the modulated train detection signal. Since transformer T3 is a common collector load for both transistors, the two signals are summed. The two halves of the winding on T3 are bifilar, since close coupling discourages parasitic oscillations. There is an internal shorted turn to increase gain stability and to raise output transistor collector impedance by lowering base impedance. Because Q9 and QlO are high-gain Darlington power transistors, Q7 and QB easily provide sufficient drive power so that no intermediate amplification is necessary. For the cab-signal-only board (-1902), both Q7 and Q8 are necessary to maintain balanced de currents in the primary of T3. In this case, a jumper must be in place at points A and B near switch S2 to properly bias QB. To obtain stable operation, the two halves are bifilarly wound, and there is a shorted turn for an internal load.

4-14

UNION SWITCH & SIGNAL ffi Because of thermal considerations, Q9 and QlO are physically loca7.ed with their heatsinks on a separate printed circuit board (N451054-9302). For the same reason, the emitter resistors are mounted directly to the backframe of the card file in which the transmitter board is installed. These externally located parts are identified by dashed boxes on Figure 4-11.

The output amplifier is a class B push-pull design capable of about 25 watts output in the frequency range from 1 to 6 kHz. Resistor R20, diode D4 and resistor R21 permit adjustment of the operating de base bias, while SPl and SP2 protect the power transistors from surges originating on the tracks or connecting cable. Output transformer T4 matches the amplifier to the minibond-coupling unit which actually transfers the signal to the rails.

The power supply for the twc transmitter boards is 24 Vdc. A separate de supply terminal allows the cab signal channel to be switched on and off independently from the train detection channels.

4.3.4 Receiver Input PCB (See Figure 4-12.)

The receiver input PCB filters and amplifies the signal obtained from the tracks. A four-pole linear phase bandpass filter rejects noise appearing at receiver input terminals 11 and 13. Transformer Tl matches the filter input impedance to the signal source. The filter consists of Ll, L2, T2, T3, Cl, C2, C3, C4, Rl, R2, Rl4, and RlS.

The filter output voltage is applied, along with a Zener regulated de bias voltage, to amplifier Q2 through a resistive voltage divider consisting of R8, R9, . and RlO. Resistors R8 and R9 are selected during factory testing to obtain the receiver sensitivity. Transistor Q2 amplifies the signal prior to demodulation. Its emitter circuit consists of a network of resistors, one of which is variable with temperature. This network allows the receiver gain to vary with temperature to compensate for the variations in the input filter characteristics. Capacitor cs and transformer T4 in the collector circuit of Q2 resonate at the receiver operating frequency, but the Q of this circuit is very low and does no~ add appreciably to the overall selectivity. The secondary of T4 supplies a push-pull voltage to demodulator diodes D3 and D4 which rectify the carrier signal. The positive de voltage obtained by demodulat:on adds to the emitter potential of Q3, thus increasing its range of :inear operation. A low-pass filter network, consisting of RlO and C6, removes the carrier from the demodulated signal; Q4 then buffers the signal in an emitter follower configuration. Fuse Fl protects against shorted components on the board, and R21 and C7 filter noise from the power supply. The common lead of the power supply is in series with the metal cans of the carrier filter pot cores to ensure that the filter components remain mechanically intact.

4-15


4.3.5 Receiver Synchronous Rectifier PCB (See Figure 4-13.)

Aside from a 24 Vdc power supply, two signals are required for operation of this circuit. One is the signal acquired from the Receiver Input PCB; the second is a reference signal obtained from the Coder/ Oscillator PCB (N451570-830X), or from the Line Transmitter/Receiver PCB (N451570-3101). In either case, the reference signal is a 24 Vp-p square wave in the 5 to 30 Hz range. The code rate reference is opt~cally coupled through IC3 to a circuit consisting of CMOS integrated circuits ICl and IC2. ICl is a dual precision timer and IC2 is a quad NOR gate. IClA delays the falling edge of the reference signal and IClB delays the rising edge. Although the square wave reference signal is sharp-edged, opto-isolator IC3 has a relatively slow response. To restore the sharp edges, IC2A and IC2B are connected as a noninverting Schmitt trigger which also nullifies any noise appearing on the reference signal input. The signal at pin 3 of IC2B is in phase with the code rate input signal, and drives the remaining circuits.

Each negative edge at pin 5 of IClA produces a positive output pulse at pin 6. The time duration is determined by R22, R23, and C9, and can be varied from about 5 to 55 msec. IC2C is used as a negative logic NAND gate. When either or both inputs to IC2C are high, its output is low; only when both inputs are low can its output go high. Therefore, the leading edge of the output signal of IC2C is delayed for the duration of the positive pulse produced at pin 6 of IClA. Similarly, for each positive edge of the signal at pin 12 of IClB, a positive pulse is produced at pin 10. The duration of this pulse is determined by R24, R25, and ClO, and is variable from about 5 to 55 msec. IC2D is used as a NOR gate so that either the high signal (with delayed leading edge) from IC2C or the positive pulse from IClB drives the output of IC2D low. The pulse from IClB is thus added to the end of the pulse with delayed leading edge. The output of IC2D is a 12-volt square wave with both edges independently delayed from the original square wave reference input signal. This delayed square wave drives Q9 and QlO to actuate relay RLYl.

The other input signal for the synchronous rectifier is obtained from the Receiver Input PCB and applied to pin 14. This signal is the demodulated signal acquired from the track, and has the same frequency as the reference code rate. Transistors Ql and Q2 buffer the signal and provide a low impedance source for the primary of Tl. This transformer is designed to operate at code rate frequencies between 5 Hz and 30 Hz, and provides a step-up turns ratio of about 1:4. The secondary of Tl is connected to the contacts of RLYl in such a way that full-wave rectification is produced when the heels of the relay switch synchronously at the code rate frequency. Looking at Figure 4-13, if the relay contacts are as shown and the GR wire is positive with respect to Y, then capacitor C2 receives a positive charge. When the polarity of the secondary voltage reverses on the next half-cycle, the relay contacts also reverse, so that again C2 is charged positively. Thus, C2 receives a positive increment of charge on each half cycle. If the input signal is not exactly synchronous with the switching

4-16

..


of RLYl, then C2 is sometimes charged positively and sometimes negatively. The resultant voltage is the average of these events. Capacitor C2, along with the winding resistance of Tl, constitutes a lowpass filter with a cutoff frequency of 0.5 Hz. Note that the negative side of C2 is connected to the +24V line. The positive voltage which is generated across C2 is more positive than the power supply voltage, which is the only way such a voltage can occur in the receiver. This also makes it possible to detect shorts and leaks in Tl. The connection to the power supply is checked by a Kelvin connection which supplies voltage to transistor Q4. A broken trace which removes the +24V line from the transformer also disables Q4, resulting in a detectabie failure condition.

The voltage developed across C2 is applied to a level detector consisting of Q3 and associated components. The level detector is a Colpitts oscillator with the feedback path from collector-to-emitter arranged in series with Zener diode D3. As long as D3 does not conduct, the oscillator feedback circuit is open. As D3 begins to conduct, its dynamic ac impedance drops very rapidly with increasing de voltage. Since D3 is selected to have a very sharp Zener knee, the change in de voltage from non-oscillation to full oscillation is less than 100 millivolts. Thus, the oscillation threshold actually occurs at a de voltage slightly higher than the rated Zener breakdown voltage. Diode D2 is a constant current diode which raises the equivalent de

-resistance of the level detector, and allows Tl to be smaller than would otherwise be possible.

If the level detector is oscillating, then the 20 kHz output signal is transformer-coupled to the base of Q4. Transistors Q5 and Q6 further amplify the 20 kHz, and drive a half-wave voltage doubler consisting of C6, C7, DS, and D6, thereby producing a de voltage of about -BV. Transistors Q7, Q8, and associated components, form a time-delay circuit to reduce the likelihood of a track relay picking due to momentary loss of shunt. Transistor QB is a switching transistor that controls the current to the track relay. In order for Q8 to switch on, Q7 must also switch on. This can happen only when its base voltage exceeds the emitter bias established by Rl5 and D7. Furthermore, in order for the base voltage to rise, capacitor CB must charge through resistor Rl3. Thus, although the negative de voltage is produced immediately when the level detector oscillates, the voltage is not applied to the relay until CS has charged sufficiently to switch on Q7. If, while C8 is charging, the negative de disappears, then C8 begins to discharge through Pi6 and the emitter-base junction of Q7. Thus, C8 must charge through a high value of resistance (Rl3) but discharges through a much lower resistance (Rl6). This produces a slowpick, fast-drop characteristic. Resistor Rl8 and diode D8 snub the track relay and limit its reverse EMF on deenergization. Fuse Fl protects against short circuits on the board, and R27 and Cll decouple the power supply line. Resistor R28, diode Dll, and capacitor Cl2 provide a filtered 12 Vdc for operation of the CMOS circuits.

4-17


4.3.6 Line Transmitter/Receiver PCB (See Figure 4-14.)

The Line Transmitter/Receiver PCB consists of two completely independent circuits. The transmitter circuit accepts an input square wave in the range of 5 to 30 Hz, and with an amplitude of 24 volts peak. This signal is optically isolated from a driver circuit operating from a line battery power supply. The isolated signal drives a two-wire transmission line. The other end of the transmission line is connected to the input of the receiver portion of a similar board, which may be up to 12,000 feet distant. The signal is again optically coupled to a Schmitt trigger circuit which removes noises and restores the waveshape. The output of the receiver is a 24 volt peak square wave, in phase with the original signal source, except for the transmission delay time. (See Figure 2-3.)

4.3.6.1 Transmitter Circuit. The line transmitter circuit is comprised of transistors Ql, Q2 and Q3, optical isolator ICl, and associated components. Ql drives the light emitting diode element of optical isolator ICl. The other element of the optical isolator is a photon-sensitive field effect transistor (photo-FET). The photo-FET acts as a variable resistor in response to the light generated by the LED. Thus, the voltage at the junction of R4 and RS varies in response to the signal input to Ql. Transistors Q2 and Q3 are connected as a Darlington switch to provide high gain and high current capability. The collector load for Q2 and Q3 has two branches: one branch is through R7 and LEDl, which provides a visual indication of circuit operation; the second branch is through RB, R9, and the external pair of wires with its distant receiver. SPl is a metal-oxide varistor that protects Q2 and Q3 from destructive transients and noise which may appear on the pair of wires. Resistors R8 and R9 limit the current through the external circuit; RlO and C2 filter the line battery source; and F2 protects against the possibility of a short circuit on the PCB.

4.3.6.2 Receiver Circuit. The line receiver circuit consists of optical isolator IC2, transistors Q4, QS, Q6, and Q7, and associated components. The line input is current-limited by resistors R24, R25, R26, and R27; SP2 is a metal-oxide varistor to protect against destructive line transients, and Dl protects the optical isolator LED from reverse voltages due to transients. The operation of IC2 is identical to ICl in the line transmitter section. The voltage at the junction of Rll, Rl2, and C3 varies in response to the current through the LED element of IC2. C3 removes high frequency noise and transients from the signal. Transistor Q4 is an emitter-follower amplifier to buffer the recovered signal before it is applied to the Schmitt trigger consisting of QS, Q6, and associated components. The Schmitt trigger has sufficient hysteresis to protect against a difference voltage of about 2.5 volts on the pair of wires. In addition, waveform distortion due to line capacitance and other causes is removed. Transistor Q7 is switched to provide both proper output phase and voltage level for external circuitry; LED2 visually indicates if a signal is being received.

4-18

UNION SWITCH & SIGNAL tE 4.3.7 Berthing Timer PCB (See Figure 4-15.)

The Berthing Timer PCB is etabled by a berthing application input signal of 24 Vdc at pins l,A and/or 9,K. Each board consists of two identical circuits. Diode Dl provides a regulated 7.SV supply to ICl, which operates as an astable multivibrator. The frequency and duty cycle of the asymmetric square wave output at R3 are determined by Rl, R2, C2, and C3. Output driver Ql provides current and voltage gain, and MOVl protects Ql against high voltage transients. Except for different reference designations, the IC2 circuit operates identically.

4.3.8 Tuning Panel Circuit (See Figure 4-6.)

The tuning panel contains an integral PCB that contains two pairs of switch-selectable decade capacitors. As shown on Figure 4-6, each decade capacitance network spans the values from 0.0 uf to 0.11 uf. The FINE switch selects values between 0.0 uf to 0.01 uf in steps of 0.001 uf. The COARSE switch selects values between 0.0 uf to 0.1 uf in steps of 0.01 uf. Each decade capacitor is connected to a terminal board for external wire connections between the transmitter, receiver and minibond coupling unit at the track.

4.3.9 Coupling Unit (See Figure 4-7.)

The coupling unit consists of two toroidal inductors and several capacitors which are encapsulated in polyurethane within a welded steel enclosure. Two opposite ends of the steel enclosure are open. On one open end a weather-proof cable grip permits access to the input terminals of the coupling unit. Extending from the other open end is a three-conductor cable which is used to make electrical connection to the minibond. Flanges on the steel housing are provided with holes which permit the coupling unit to be attached to the minibond.

Although the coupling unit is physically attached to a minibond in service, the two separate units are not electrically matched. Thus, any coupling unit can be used with any minibond. For convenience in ordering, a series of part numbers (N451003-09XX and -lOXX) have been standardized which call for a coupling unit already mounted to a minibond. Even in this case, the coupling unit and minibond are not considered to be matched, so that either one may be independently replaced.

In order to test a coupling unit, it must be electrically connected to a minibond. A standard minibond may be retained and used for testing all coupling units. If the coupling unit is already attached to a minibond and if the minibond is known to meet its separate test specification, then the coupling unit may be tested with the minibond to which it is attached.

4.3.10 Minibond Unit (See Figure 4-8.)

The minibond is a transformer with two windings on a toroidal magnetic structure. The primary consists of two turns of copper with a crosssectional area greater than 2,000,000 circular mils. This winding is

4-19


4-20

0.003

ca

C1

FINE 1 COARSE 1

FINE 2 COARSE 2

Figure 4-6. Tuning Panel, Schematic Diagram

TB1

TB2

Cl

L1

B

A

C4

c

B

C2

L2

COUPLING UNITS N451052-3201 THROUGH -3204

Cl C2

Ll L2

COUPLING UNITS N451052-3401 THROUGH -3405

UNION SWITCH & SIGNAL 133

C3

C3

TO BOND

(W)

(BK)

TO BOND

(W)

Figure 4-7. Three-Frequency coupling Unit, Schematic Diagrams

4-21


CT

P1 P2

Figure 4-8. Minibond, Schematic Diagram

4-22

UNION SWITCH & SIGNAL 83 connected to the rails and m~st carry de propulsion return current. This winding is center-tapp~~ for connection to other minibonds on the same or adjacent track, or tc the propulsion rectifier return conductors. Since the de current :lows in through terminals Pl and P2 and out the center tap, the de magnetic fluxes in the core oppose each other and tend to cancel.

The secondary winding consists of many turns of much smaller wire around the toroidal core. T~is winding is used in conjunction with a coupling unit to tune the mi~ibond to its train detection and cab signal frequencies. This wi~iing is connected to the electronics in the train control room via a twisted pair cable. Transformer action between the primary and secondary windings allows signals to be exchanged between the track a~d the train control room equipment.

4-23/4-24

•2•

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2,21(

01 IDV INT5U

-vcc ©

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05KI 06

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IN914

RJI IOOK

015

-vcc©

R21

" 2151(

R22 SOT

R24 SOI

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011 2NJ! I 1

l:~=~'§S6~'


WARNING:

----------· THIS IS A VITAL SAFETY

CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIR· CUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

NOTES,

8 ·~g:gN{~lr: y~~UHEl·:~s~ES~t~~;r~Vo-sH. 83'

CO~ONENT NOMENCLATURES c20.c21, C25,R55,R56,01 8 010 ARE NOT US£0

D 451626-3601 REV O

Figure 4-9. Coder/Oscillator PCB (1590 Hz and 2670 Hz),

Schematic Diagram

4-25/4-26

.,.

l·g 1.11

Cl 01

RI IOV 1Nl58A 510,

C2 O,IP"

2 200,

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0

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en

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(4066)

.. 'Ji

-vcc ® -I JVOC

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r JJ

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NOTES,

~ • i~~~lr r:~ui!rl":;srS~E~~~r!Vo-SH, 93 1

In,, ~~~~~J1NMfgt!~~R~T uffg.c21,c25.

THIS JS A VITAL SAFETY CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIR· CUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

D 451626-3602 REV O

Figure 4-10. Coder/Oscillator PCB (3870 Hz and 5190 Hz),

Schematic Diagram

4-27/4-28


r-----------------------------------------------------··-

CODE RATE

GENERATOf\ !,J I

Fl

TPI !OJ

ENAitt f---0-·~2~5~A-~~----4~-----~ 116, Tl

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C.lB /_ __ Y RI C~RRIER '\,-~--.. ---

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0741 ~~ 'f, ll,Al~-~------12,B J

TPIO I lllNJ - c,

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l :~:~: ( r r· 03

IN753A

nrs 3.JK

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I.I

~~Jl~Q

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r------------,r----,r-------------, I IIOL,IIM) II ~ II (40.SEJ I I II RI .[ R3 II I I 09101) £ l(IR2J,C: !R<llJ £ 010(02> I

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( 12,N) 13,P

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R9 I OK

RIO IOK

C4 I .Qµr

WARNING:

THIS IS A VITAL SAFETY CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIRCUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

8 SEE TABULATION DWG F451510 SH.19

Ii::,. PART Of CARDF I LE ASSE'-IJL Y. IDENTIFIED AS RI 8 R3 FOR LEFT HALF OF CAROFILE AND AS R2 8 R4 FOR RIGHT HALF, SEE N451082 SH. 10,

09 8 010 MT'D ON SEPARATE PC BOARO N451054-9J02, 09 ON THIS SHEET CORRESPONDS TO QI ON F451054 SH,A3, ANO 010 CORRESPONDS TO 02 ON THAT SHEET.

WARNING THIS JS VITAL SAFETY CIRCUIT, ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COM'ROMISE THE SAFE PERFORMANCE Of THIS CIRCUIT. ALL COMPONENTS SHALL BE REPLACE ONLY BY THOSE SPECIFIED ON THE usas BILL OF MATERIAL.

FOR A -1902 BOARD WHICH IS USED FOR TRANSMITTING ONLY A CAB SIGNAL, ALL OF THE COt.f'ONENTS TO THE RIGHT Of THE DASP.ED LINE

:R~l~~1~0f.!lt~Rft l~[DfA~guJlT~t~0rof~~s A AND B.

D 451315-7601 REV 6

Figure 4-11. Transmitter and Power Transistor PCBs,

Schematic Diagram

4-29/4-30

INPUT

TP2 !Gl TLI JPI TU

111,lllf>---------, ~RI• Cl~Lt•) ~n~• TRACK Q.C2•

•• II 3, P 10--------,-J --__,- - ------------- -1 Tl• 6 T2•

T 3 !G> TL2 TU

TP4 !Will

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, I , NOT

--~ _j_ ' C 01

R6 1\'-_-/_ DI

N9598 (8,2VI

Jl'2

02 I N914A

USED

1"l5 RS Tl6 • ~-·A,/\/",-~ •

s. (). T. ! COARSE>

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C7 , oo.,r

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Rrs I. SK

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TPG TBNI

R2 I f I

I 0° I 12A

POT CORE CANS

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TPS ( Yl

NOTE•ALL RESISTORS ARE T 14W, 51 COMPOSITION UNLESS OTHERWISE NOTED FOR COMPONENTS MARKED (II SEE TAB, ON owe. f451570-SH,30

RESISTORS R7 ANO Rl4 ARE OMITTED

B24R ! I ,A> ! 2. 8 >

oo.«)ou 1_-. r t:i'J SlCNAL 11,H I

0451315-8701 REV4

Figure 4-12. Receiver Input PCB, Schematic Diagram

4-31/4-32

CODE RATE INPUT

WARNING:

16,T

FROM mwi

TPT IBU>

l l~,RI


TP3 CG)

01 tN•003

•12

IC3 HI 181

TI

BK.

Cl4

RLYIA !;R_. __ ._

•

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IOQpr '---'1,N'---t-~Vl/~--.-------·--11---------------,

NOTES•

&. ,c, -1,«;1 •sJs ICZ-~14001 IC3-HI 181

2 ALL RESISTORS ARE I 1• W 51 COi.POSITiON UNLESS OTHER Ill SE NOTED

~ RELAY RLYI wsr BE PROPERLY ORIENTED DURING • TESTING or PCB, POSITION PCB, IN SUCH A MANNER THAT THE ARROII ON THE RELAY POINTS UPIIARO.

£ HEATSINK

+ 12

3

J_ C2

HP'

+12

TL I

02 I N5289

I ,HMA!

RJ I ,BK

03 LVA450 5.ov

RS SIOK

03 2NS962

RIO 20K

04 ~ 2N5962

10~1., -----t~·OJ7 i~J~=- -~- -R4 10 R 1 RI I 04

• HI 7 >1 ,!1Y,

~~-°.:_r5f,µtl IK ?4K l IN4001

v t

R23

R22 - +12 5, IK

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+12......__

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9 "D"

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•12

•12

10

05 IN914A

Tr? (0)

Cl 2

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010 IN914A

R28

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01 I I N963B

12V

RIG IK


115.Sl -RY

08 I N4003

() (II ,U I HlY

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I IZA R27 B2•R

I I ,Al 1 2 .e,

+ Cl I IQQµt TP6

T I' \ N24R

~ Q 118,Vl

+24

+ RLYI

-&

D 451315-8601 REV 6

Figure 4-13. Receiver Synchronous Rectifier PCB,

Schematic Diagram

4-33/4-34

TP3 < G l

CODE AATE IN

< 6. Fl

TPI ( )

• 001 µr

01 2N3643

824-0u>---1t---...... o~·~S•A---~l~O~..n.:::..:::::. ___ ~~ (l,A) +24 Fl R23

rTP2

N24-0 -~,__<_B_N_> ------------~1 t~Oµr (18,Vlo ~

R-HI (SA,1/2 WT 4711,112 WT (12,Nlo--------__:_::__:,0

R24 R26

SP2 IN4003 01

UNION SWITCH & SIGNAL tE TPS ( 0)

r-~~~~~~~~~~~,-~~~~~~~~~~...-~~~~~~~~~l~O~A--_;;.,0,5A RIO F2

LB (3,C)

IK R3

+24

4,7K R4

RII 1'S.O.T.~

+24

04 N3644

02 N3643

47K R6

LINE RECEIVER

DRAWING D451315 SIL 8801, REV. 2

68QA

R7

03 N2270

LINE TRANSMITTER

+24 +24

2K Rl7

WARNING:

06 N3644

THIS IS A VITAL SAFETY CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIA· CUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

+24

'l LED2 .5092.-4415 tK

TP6 < Wl

I LN 0 Cl6.T)

R21 TP4 ( y )

22QA < 14, R l

R22

07 2N3643

CODE AAT£ OUT

NOTE1 I, ALL RESISTORS l/4 WATT, 51 TOLERANCE

UNLESS OTHERWISE NOTED.

£ VALUE OF RII IS BETWEEN 5.IK 8:. 39K.

Figure 4-14. Line Transmitter/ Receiver PCB, Schematic

Diagram

4-35/4-36

~Rlc!!>l!!>TOR!!> Rl,R2,~ &.R7 }\.!, f': OW!!,' ' OLL

N4515it · -1801 • 1802

RI ,R6 681K• IK

R2,R7 681K• 487K•

•I/BW,11

+

+

Cl 47µ{'

C6 47µ('

'----•1 4 8

DI IN!IOll& 7.511

I-C2 ·----- C3 _______ .

R3

~--_.2 ~~~ 3 ------"-A,"----·1.-470n

C4

_6_I5 _ I

cs lf

___ _J~~__C_ '']._

02 IN!W>ll6 7.5\f

C7 6.0.T.

R6&

R7£

ca 1.sµr

7

2

6

C9 ,Olµf'

4 8

IC2 555 3

5 I

RS -~-·

Joo• 2 w

R8

• fJI/Jf'

~-c CIO -11-·

• 01111·

RIO

300° 2W

QI MM~OI

02 HH'4001

MOV I '119SLA,A.

MOV 2 V'9SLA7A

rt

IAMP

F2

IAMP


l,A

... / I. r:

1~.v

9,K

11,M

18.V

D 451315-7301 REV 3

Figure 4-15. Berthing Timer PCB, Schematic Diagram

4-37/4-38


SECTION V

FIELD MAINTEKANCE AND TROUBLESHOOTING

5.1 GENERAL

Field service maintenance ana troubleshooting for the AF-400 System is accomplished at two levels; namely, preventive (scheduled) maintenance and corrective maintenance. Both of these maintenance concepts are important, especially the former, since it decreases the possibility of equipment downtime. The maintenance tasks outlined herein apply to the AF-400 System electronics in the cabinet card files and the system power supplies. For maintenance procedures relative to the coupling unit, minibond, and track circuit relays, refer to the applicable service manual.

5 .2 PREVENTIVE ( SCHEDULED) J.'iA.INTENANCE

Preventive maintenance is a scheduled process whereby the AF-400 System components are inspected, cleaned, and tested on a periodic basis to ensure that all functions are operational, to detect future probable causes of equipment malfunction, and to preclude the possibility of a system breakdown that could seriously impair operation of the rail transit line. The following paragraphs describe cleaning, inspection, and minimum perforffiance test procedures for the AF-400 System.

5.2.1 Importance of Preventive Maintenance

The responsibility of maintenance personnel is to keep the AF-400 System in a satisfactory operating state; when an equipment failure occurs, the fault must be quickly corrected. However, the most important phase of maintenance is the prevention of failures before they occur, rather than the location and correction of a failure after it has occurred.

Prevention of failures in the AF-400 System is accomplished by regular inspections, tests, and servicings that are performed as specified in this section. Regular and thorough preventive maintenance is simply good housekeeping. It includes cleanings, inspections, and tests. Additionally, it includes keeping accurate records of when preventive maintenance routines are performed and their results. The records can be used to establish a thorough maintenance pattern, and detect equipment and circuit performance deterioration. This detection permits corrective action to be taken before deterioration eventually causes a failure that could halt train traffic.

5-1


5.2.2 Cleaning

Cleaning of equipment is necessary to remove dirt and other substances from equipment that, if allowed to accumulate, can cause corrosion or otherwise impair proper operation. In some instances, if equipment surfaces are extremely dirty, cleaning permits routine inspections (paragraph 5.2.3) to be performed properly by exposing equipment surfaces.

5.2.2.1 Equipment Cleaning. The AF-400 System equipment cabinets and power supplies installed in the equipment room need to be cleaned, as required, every three months. However, they must all be cleaned at least once a year.

5.2.2.2 Agents and Materials Required. Table 5-1 lists the cleaning agents and materials required to clean the AF-400 System equipment, and their uses.

Table 5-1. Cleaning Agents and Materials

NAME MANUFACTURER USE

Household Cleaner (Mild Liquid)

.Lint-Free Cloths

Commercial

commercial

Cleaning exterior surfaces

Cleaning and drying exterior surfaces

Soft Bristle Brush Commercial Removing dust and foreign matter from terminal blocks, electrical connections, and equipment surfaces

Compressed Air in Aerosol Can

Commercial Blow foreign matter and dust from electrical surfaces

5.2.2.3 Cleaning Procedure. Clean the AF-400 System cabinets, and power supplies as follows:

5-2

I WARNING -

HAZARDOUS VOLTAGES AND CURRENT MAY BE PRESENT. EXERCISE CAUTION WHEN WORKING NEAR EXPOSED TERMINALS. NEVER USE WET CLOTHS NEAR EXPOSED ELECTRICAL TERMINALS.

a. Remove dust and dirt from accessible surfaces, using soft bristle brush.

b. Blow out dust and dirt from inaccessible areas around terminal blocks, fuse holders, and other areas where live electrical conductors are exposed.

UNION SWITCH & SIGNAL EE c. Wipe power supply sur:aces and cabinet exterior and interior

surfaces (not exposec electrical conductors) with a lintfree cloth dampened ~ith a solution of water and household cleaner, so that all dirt and foreign matter are removed.

d. Dry dampened surfaces with lint-free cloth.

WHEN USING COY2RESSED AIR TO BLOW OUT DIRT AND DUST PARTICLES FROM CARD FILES, ALWAYS DIRECT AIR AT Ali. ANGLE RELATIVE TO THE PCBs OR LOOSE OR DP~J'...GED COMPONENTS COULD RESULT.

e. Using compressed air or soft bristle brush, remove dust and dirt particles fro~ cabinet card file and tuning panels.

f. Collect all accumulated dust and dirt and discard outside equipment room in accordance with railroad directives.

5.2.3 Routine Inspection (An~ually)

A routine inspection consists of observing the appearance and actions of each ~quipment item under inspection. Appropriate cleaning of the item, as described in paragraph 5.2.2, may have to be accomplished before the inspection can be made. In addition, it is necessary for maintenance personnel accomplishing the inspection to know the manner in which the equipment is supposed to function. During the inspection, the appearance, smell, sound, and feel of the device can then be used to make a judgement as to whether the device appears to be functioning properly or an obvious faulty condition exists. At least once a year, the AF-400 System power supplies, cabinets and their components should be subjected to a cursory inspection (preferably at the time of cleaning). To perfor~ a routine inspection of the AF-400 System power supplies and cabine~ equipment, make the following checks and observations:

a. Power supply housinss and cabinet exterior are clean and free of scratches, chipped paint, and spots of corrosion.

b. Cable connections to power supplies and at rear of card files are tight; wires are secure and free of nicks, cuts, and fraying.

c. Connections to tuning panel terminal boards are tight and wires are free of nicks, cuts, and fraying.

d. All card file PCBs are securely mounted in guides and bottomed in card edge connectors.

e. PCB components are securely mounted and show no visible signs of deterioration.

5-3


5.2.4 Minimum Performance Tests

Minimum performance tests demonstrate that AF-400 System functional circuits and equipment items are functioning properly. A performance test can consist of performing normal operating procedures and observing that required equipment responses are correct, or, using test equipment, measure the equipment responses. Unacceptable conditions identified during tests must be corrected immediately. Performance test failures may require isolation of faulty performance to the lowest replaceable unit (LRU). The LRUs for the AF-400 System are listed in Appendix A. When a functional circuit's performance is not acceptable, the faulty LRU must be identified. Occasionally, adjustments may be required to bring the LRU's performance within required operating limits. Performance tests for the AF-400 System should be accomplished on a periodic six month basis to ensure that all functions meet minimum performance criteria. Refer to Section III for AF-400 System adjustments and minimum performance tests.

5.3 TROUBLESHOOTING

Data and procedures that can assist maintenance personnel in localizing AF-400 System faults to the lowest replaceable units (LRUs) or associated wiring are contained in this section. The troubleshooting procedures are presented in the form of fault isolation logic diagrams and are based upon the results,· or lack of results, observed during the minimum performance tests in Section III.

5.3.1 Troubleshooting Approach

Troubleshooting procedures are developed to guide maintenance personnel in the logical sequence to be used in isolating a fault; they are prepared by analysis of normal indications (or operation) versus abnormal indications or symptoms. Most of the initial system fault indications or symptoms are those observed external to the AF track circuit electronics, such as the operation of vital relays. Additional indications can then be obtained from AF track circuit PCB LED indications in the equipment card files. Localization of some faults include the use of test equipment.

No detailed group of fault isolation flow diagrams, no matter how thoroughly prepared, can be guaranteed to accurately locate every possible cause of trouble that could occur in the AF-400. Maintenance personnel can use the fault isolation flow diagrams in this section as an aid. With the majority of faults that could occur, the flow diagrams are accurate. However, there are always combinations of faults, or intermittent faults, that can be accurately diagnosed only on the spot. They present maintenance personnel with the greatest challenge in accomplishing the task of quickly returning a faulty subsystem to full operation.

5-4

UNION SWITCH & SIGNAL '33 The responsibility of maintenance personnel is to locate the cause of a failure and eliminate it quickly; this can be accomplished by using a systematic troubleshooting approach for all faults encountered. Such an approach has been used in developing the fault isolation flow diagrams included in this section. The approach is not new. It has been used successfully in trc~bleshooting various types of electric and electronic systems, equipments, and circuits. There are six steps to the systematic approach:

a. Trouble symptom - the trouble symptom lets maintenance personnel know that something is wrong and provides clues that show where to look for the trouble.

b. Sectionalize - each system, subsystem, and equipment is divided into functional sections. Analysis of the trouble symptom directs maintenance personnel to the trouble section.

c. Localize - each functional section is divided into circuits or removable components. Through observations and measurements the fault is localized to a circuit or removable component such as a PCB.

d.

e.

Isolate - within the localized circuit on the field, or within the removed and repairable component in a shop, the faulty component is isolated through visual inspections and measurements.

Repair - the trouble is corrected by adjustment or component replacement. (Refer to Section VI.)

Check operation - the equipment is never assumed to be repaired by correcting one fault. Always check for proper operation to verify repair.

For field maintenance, step d. of the general procedure may not be necessary. This occurs when trouble is localized to a replaceable component such as the receiver input PCB during step c. In such cases, the isolation portion cf the troubleshooting procedure (step d.) is performed in a shop when a defective but repairable component is returned to the shop for repair. Shop maintenance and troubleshooting are described in Section VI.

The systematic troubleshooting approach identifies and corrects trouble in the shortest time. It is the only effective approach. Guessing or testing at random are seldom effective and usually result in nothing more than lost time. To be capable of applying the systematic approach, maintenance personnel must:

a. Know how the subsystem accomplishes its functions

b. Be able to read and understand circuit and wiring diagrams

s-s· ·


c. Be able to use test equipment and interpret their readings

d. Have a thorough understanding of AF-400 System PCB circuit operation.

5.3.2 Recommended Test Equip~ent

The test equipment recommended for field maintenance and troubleshooting of the AF-400 System is listed in Table 3-1.

5.3.3 Other Troubleshooting Considerations

In addition to logically pursuing the cause of an AF-400 System fault using subsystem fault isolation flow diagrams, maintenance personnel should also have available at least one spare board for each unique board in the track circuit and files. This will permit board substitution and facilitate repair when a fault has been localized to a PCB. When substituting circuit boards, make sure that the new board is the correct part, that it is operating properly, and that it is correctly installed in the card file. Part number information for each of the various PCBs can be located in Appendix A.

5.4 FAULT ISOLATION FLOW DIAGRAMS

Troubleshooting procedures have been developed to guide maintenance personnel in the logical order of isolating a fault. The analysis of normal indications in relation to faulty indications is stressed, and this information is presented in the form of fault isolation flow diagrams.

These diagrams have been prepared on the basis of fault indications observed during operation or during a performance test routine. Each diagram is comprised of a series of questions that may require an observation or measurement. The observation or measurement will result in~ yes or no answer that will progressively narrow the area of the possible fault. The "yes" result is represented by a solid line on the diagram, whereas the "no" result is represented by a dashed line. Each diagram includes sufficient information to enable maintenance personnel to refer to other subsystems if they are suspected of causing the trouble.

Three types of boxes are used to present the data included in the troubleshooting flow diagrams. These are:

5-6

a. Shaded boxes (right and bottom border lines are heavier weighted) - these boxes contain questions that are answered by observation without a test setup or using special test equipment.

b. Single-line boxes - contain questions requiring measurements with external test equipment.

UNION SWITCH & SIGNAL t33 c. Double-line boxes (instruction and conclusion boxes) - list

the functional area or LRU that is the probable cause of the malfunction. This box may reference a procedure (adjustP.ent or performance test), another flow diagram in this manua:, or another manual to further isolate the fault. In addition, these boxes outline instructions to be followed, thereby providing direction to maintenance personnel during the fault analysis process.

The symptoms of trouble are contained in Table 5-2 together with a reference to the fault isolation flow diagram that contains the appropriate troubleshooting information. The fault isolation flow diagrams assume the following conditions.

a. When a relay is the suspected cause of the trouble, it must be removed and its coil and/or contacts must be tested before the relay is replaced.

b. To check a fuse, power is turned off, and the fuse is removed and checked with a multimeter for continuity.

c. When checking a relay energizing path, use a voltage test.

Table 5-2. Troubleshooting Symptoms

SYMPTOM PROCEDURE

AF track circuit relay deenergized when block unoccupied

Train doors will not open when train properly berthed at station platform and adjacent track circuits unoccupied

Track circuit bounded by insulated joints shows occupancy when unoccupied

Train receives stop command when track circuit is entered and adjacent blocks are unoccupied

5. 5 CORRECTIVE MAINTENANCE

Figure 5-1

Figure 5-2

Figure 5-2

Figure 5-3

Corrective maintenance is an unscheduled process whereby an AF-400 System malfunction, which has been localized through the fault analysis process, results in removal/replacement of an LRU and testing of the system after corrective maintenance is complete. The following procedure outlines a brief removal/replacement process for the card

5-7


file PCBs in the system cabinets. For corrective maintenance procedures relative to the external track circuit equipment, refer to the applicable service manual. Individual board alignments and adjustments are performed at the shop maintenance level. (Refer to Section VI.) Remove and replace card file PCBs as follows:

5-8

a. At front of card file, place thumbs on outer tabs of upper and lower board ejector on PCB in question, and simultaneously press board ejector tabs inward until PCB unplugs from card file connector.

b. With one hand, withdraw PCB straight out from board guides and remove PCB from card file.

c. Install replacement PCB in board guides and slide in until PCB contacts card file connector.

d. Place thumbs over inner tabs of board ejectors and press in firmly until PCB connector bottoms in card file connector.

......

TRACK CIRCUIT RELAY DEENERGIZED WHEN BLOCK UNOCCUPIED

--

n

LED ON RECEIVER SYNCHRONOUS RECTIFIER PCB ON?

l

L __ I I

TRACK CIRCUIT TO LEFT OPERATES NORMALLY WHEN UNOCCUPIED?

I I I I

CHECK TRACK CIR-CUIT WIRING AND BONDING. CHECK TRACK CIRCUIT ENTRANCE BOUN-DARY COUPLING UNIT AND MINIBOND AND REPLACE AS NECESSARY.

CHECK WIRING BETWEEN PCB AND RELAY. CHECK RELAY AND REPLACE.

---- -, I

CODER/OSCILLATOR LED FLASHING AT CODE RATE?

I I I I

TRACK/CAB SWITCH ON CODER/OSCILLATOR PCB IN CENTER POSITION?

I

I I I

SET TRACK/CAB SWITCH TO CENTER POSITION

- I -

APPROPRIATE CODE RATE ENABLE INPUT PRESENT

--- AT TERMINALS 20, 21, 22, 23, 24 OR 25 OF CARD FILE TERMINAL BOARD?

I

CHECK ASSOCIATED CODE SELECT RELAY LOGIC FOR SPEED COMMAND CODE RATE. CHECK WIRING.

REPLACE CODER/ OSCILLATOR PCB


OUTPUT SIGNAL FROM TRANSMITTER PCB BETWEEN TERMINALS 4 AND 5 OF CARD FILE TERMINAL BOARD MODULATED SINE WAVE OF ""' 150 VRMS PEAK?

CODED TRACK CIRCUIT OSCILLATOR INPUT SIGNAL AT PIN 3 OF TRANSMITTER PCB?

I

CHECK WIRING BETWEEN CODER/OSCILLATOR ANC TRANSMITTER PCBS. REPLACE CODER/ OSCILLATOR PCB.

Figure 5-1. AF Track Circuits, Fault Isolation Logic Diagram

(Sheet 1 of 2)

5-9/5-10

A

B

SI\MF OUTPUT Sl<,NAI PRESENT AT TEllMINALS 3 AND 4 OF TUNING PANEL TERMINAL BOARD?

I

I I I

REPLACE TUNING PANEL

CODE RATE INPUT AT PIN 8 OF TRANSMITTER PCB?

I

I

CHECK WIRING BETWEEN CODER/OSCILLATOR PCB AND TRANSMITTER PCB

TllACK ClllCUll RECFIVFR INPUT Slf,NI\L L[V[L 1\1 [NIIIANC[ 10 BOUNDARY TO TUNING PANEL TERMINAL BOARD BETWEEN TERMINALS 3 AND 4 AT 0.5 VRMS?

I

I I I

TRACK CIRCUIT IN ADVANCE OPERATES NORMALLY WHEN UNOCCUPIED?

TRANSMITTER SIGNAL PR ESE NT ACROSS TPB AND TP9 OF TRANSMITTER PCB?

I

TRANSMITTER SIGNAL PRESENT ACROSS TP6 AND TP7 OF TRANSMITTER PCB?

SI\MF INPUT 1.FVFL f,l<,NI\I INl'Ul JO PllESENT BETWEEN SYNCHflONOUS TERMINALS 31 AND 32 OF RECTIFIER PCB AT PIN CARD FILE TERMINAL 14 :::::20 VP-P? BOARD?

I I

I I I I I I

CHECK WIRING BETWEEN RECEIVER HALF OF TUNING PANEL AND flEPLACE RECEIVER

-1 TRACK CIRCUIT CARD FILE. REPLACE TUNING

INPUT PCB

I PANEL

I .

L-------·---,

CHECK WIRING BETWEEN TRANSMITTER PCB AND TUNING PANEL

REPLACE TRANSMITTER POWER TRANSISITOR PCB r--

1

I

I CHECK TRACK CIRCUIT WIRING AND BONDING. CHECK TRACK CIRCUIT EXIT BOUNDARY COUPLING UNIT AND IMINIBOND AND REPLACE AS NECESSARY

REPLACE TRANSMITTER PCB

L ________ _J

,' I I L

CODF R/\lE nrr:r:nFNC[ INPUT PF1ESENT AT PIN 13 OF SYNCHRONOUS RECTIFIER PCB?

REPLACE FlECEIVER SYNCHRONOUS RECTIFIER PCB

CODE RATE REFERENCE OUTPUT AT TERMINAL 16 OF CARD FILE TERMINAL BOARD?

CHECK BONDING AND WIRING OF TRACK CIRCUIT IN QUESTION. CHECK FOR BROKEN RAIL

-

UNION SWITCH & SIGNAL EE

COD[ llATE llrJTllrNCI _ INPUT AT TEF!MINAL lfi

OF CARD FILE TERMINAL BOARD? .

CHECK CARD FILE WIRING

'-============·=·=--~~

REPLACE CODER/ OSCILLATOR PCB

CHECK JUMPER WIRE BETWEEN TERMINALS 15 AND 16 ON CARD FILE

- ·1 I I I I I I I I I I I

_J

Figure 5-1. AF Track circuits, Fault Isolation Logic Diagram

(Sheet 2 of 2)

5-11/5-12

TRAIN DOORS WILL NOT OPEN WHEN TRAIN PROPERLY BERTHED AT STATION PLATFORM AND ADJACENT TRACK CIRCUIT UNOCCUPIED

s

TRACK CIRCUIT BOUNDE BY INSULATED JOINTS SHOWS OCCUPANCY WHEN UNOCCUPIED

D

LEGEND: YES---

NO --- -

.

....

--

24 VD,C BERTHING APPLICATION VOLTAGE AT PINS 1 AND/OR 9 OF BERTH-ING TIMER PCB IN 5-INCH CARD FI LE?

I

I I I

CHECK EXTERNAL TRAIN BERTH STICK RELAY AND WIRING TO 5-INCH CARD FILE

TRACK CIRCUIT TRANSMITTER AND RECEIVER CIRCUITS OPERATIONAL (FIGURE 5.1)7

I I I I I

TROUBLESHOOT CIRCUITS PER FIGURE 5-1

BERTHING TIMER OUTPUT AT PINS 3 AND/OR 11 OF BERTHING TIMER PCB?

I

REPLACE BERTHING TIMER PCB

CHECK FOR BROKEN DOWN INSULATED JOINTS. CHECK FOR BROKEN RAIL. CHECK TRACK CIR· CUIT BONDING AND CONNECTIONS. CHECK COUPLING UNITS AND MINI BONDS

24 voe BERTH ENABLE INPUT AT TERMINAL 26 OF TllACK CIRCUIT CARD FILE TERMINAL BOARD AT BERTHING TIMER ON (0.7 SEC) TIME?

I I I I

CHECK APPROPRIATE BERTHING TIMER STICK CONTROL TRACK (TBSCT) RELAY AND REPLACE. CHECK WIRING TO RELAY.

CAB TURN-ON ENABLE OF 24 voe PRESENT AT TERMINAL 3 OF TRACK CIRCUIT CARD FILE?

l I I I

CHECK WIRING BETWEEN BERTHING TIMER STICK CONTflOL TRACK (TBSCT) RELAY AND TRACK CIRCUIT CARD FILE. REPLACE RELAY


CHECK TRACK CIR-CUIT TRANSMITTER CIRCUITS (FIGURE 5-1)

Figure 5-2. Berthing Timer Circuits, Fault Isolation

Logic Diagram

5-13/5-14

TRAIN RECEIVES ZERO SPEED COMMAND WHEN TRACK CIRCUIT IS ENTERED AND ADJACENT BLOCKS ARE UNOCCUPIED

LEGEND: YES

CAB TURN-ON ENABLE OF 24 voe PRESENT AT TERMINAL 3 OF CARD FILE TERMINAL BOARD?

l I I I

CHECK ROUTE LOCKING CODE APPLICATION RELAY LOGIC FOR ASSOCIATED TRACK CIRCUIT. CHECK WIRING

NO ----

APPROPRIATE SPEED COMMAND INPUT LINE ENABLED (TRAIN DETECTION FREQUENCY OF"" 20 VP-P) AT INPUT TO TRACK CIRCUIT CARD FILE?

I

I

TRAIN DETECTION FREQUENCY PRESENT AT TERMINAL 19 OF CARD FILE TERMINAL BOARD?

I I I I

REPLACE CODER/ OSCILLATOR PCB IN THACK CIRCUIT CARD FILE

CHECK ASSOCIATED CODE SELECT RELAY LOGIC FOR SPEED COMMAND CODE RATE. CHECK WIRING.

CAB OSCILLATOR INPUT OF 990 HZ PRESENT AT TERMINAL 14 OF TRACK CIRCUIT CARD FILE?

I

I

CAB OSCILLATOR OUTPUT FREQUENCY OF 990 HZ PRESENT AT PIN 8 OF CAB OSCILLATOR PCB IN 5-INCH CARD FILE?

CHECK WIRING BETWEEN 5-INCH CARO Ff LE AND TRACK CIRCUIT CARD FILE

.__


TROUBLESHOOT TRACK CIRCUIT TRAIN DETECTION TRANSMITTER CIRCUITS (FIGURE 5-1)

REPLACE CAB OSCILLATOR PCB IN 5-INCH CARD FILE. CHECK ASSOCIATED 24 voe POWER SUPPLY AND ASSOCIATED WIRING

Figure 5-3. Cab Signaling Circuits, Fault Isolation

Logic Diagram

5-15/5-16


SECTION VI

SHOP MAINTENANCE

6 .1 GENERAL

This section presents shop maintenance troubleshooting procedures for the LRUs of the AF-400 Syste~ which have been found defective during field maintenance and troubleshooting. Included are a listing of recommended test equipment and components; PCB and component level troubleshooting procedures including alignment and adjustment; repair procedures; and final pre-shipment inspection procedures.

6. 2 REC..OM1'1ENDED TEST EQUIPMENT AND COMPONENTS FOR SHOP MAINTENANCE

The recommended test equipment and components required for shop maintenance and troubleshooting are listed in Table 6-1; maintenance personnel should be thoroughly familiar with their use and application. Test equipment with equivalent specifications may be substituted; under no circumstances should equipment with inferior specifications be used.

QTY

1 1 1

1

1 1 1

1 1 2 1 1 1 1 1 1

'l'able 6-1. Recommer,ded Test Equipment and Components for Shop Maintenance

NOt-iENCLATURE MFR DESIGNATION ALTERNATE

Oscilloscope I Tektronix T935 475, T912 I

Oscilloscope, Storage Tektronix 5113 Differential Vertical Tektronix 5A22N

Amplifier I With XlO Probes

Frequency counter I HP 5300A Display

I With HP 5307A Front End

I

Multimeter I Simpson 260 I

Digital Multimeter I Fluke BOOOB Fluke 8000A Signal Generator wavetek 146 Exact 504,

-· 7260 Spectrum Analyzer HP 3580A Amplifier Mcintosh MC250 AC Voltmeter HP 400F Power Supply HP 6266A ( 3A) HP 6266B Power Supply HP 6205B Power Supply Harrison 6202B HP 6204B Capacitance Meter ECD Corp. C-Meter Current Probe HP 456A Hi-Pot Tester Associated

Research 404

6-1

133 UNION SWITCH & SIGNAL

Table 6-1. Recommended Test Equipment and Components for Shop Maintenance (Continued)

QTY NOMENCLATURE

1 Impedance Bridge 2 Resistor Decade Box 1 Power Decade Resistor 1 Power Transistor PCB 1 Coder/Oscillator PCB 1 Oscillator PCB 1 Receiver Input PCB l Tuning Panel PCB 1 Transmitter PCB 1 Card File l Minibona 2 Switch, SPST Toggle 1· Switch (STl) SPST(NO)

Momentary Pushbutton 1 Switch (ST2) SPST(NC) 1 Relay (TR)

1 Relay Mounting Base 1 Relay (KR} 1 Diode (DTl) 1 Capacitor, l uf, 200V 2 Resistor, 2.5 Ohm, 25W 1 Resistor, 3.9K, l/2W 1 Resistor, llK, l/2W 1 Resistor, 13K, l/2W 1 Resistor, 750 Ohm 1 Resistor, l.3K 1 Resistor, 2K 1 Resistor, 2.4K 1 Resistor (RTl), 3K, 2W 1 Resistor (RT2), lK, l/2W 1 Resistor (RT3), lK, 2W 3 Resistor {RT4, RT5, RT6},

lOK, l/2W 1 Resistor, 150 ohm, l/2W 2 Resistor, 360 Ohm, lW 1 Resistor, 6.2K, l/2W 1 Resistor, 200K, l/2W 3 Card Extenders

6.3 TROUBLESHOOTING

Y..FR DESIGNATION

GR 1608A Heath IN3117 Clarostat 240-C US&S N451054-9302 US&S N451570-830X US&S N451054-1302 US&S N451570-3002 US&S N451522-8901 US&S N451570-1903 US&S N451082-1001 US&S N451003-0701 J725681 J725326

Alco .MPA-103B US&S PN-lSOB, 400-0hm

Coil, N322500-901 US&S N334266 J726108 (24 Vdc) 1N4003, J723555 J706813 J735519-0392 J720764 J721258 J735254 J723298 J723065 J721080 J721255 J721342 J720882 J720912 J720883

J721248 J723745 J720771 J073905 US&S N398028

ALTERNATE

J725750

The procedures in the following subparagraphs are minimum performance tests which can be used to isolate a PCB malfunction to a replaceable component and to determine the operational status of the minibond and coupling unit(s}. Servicing of the PCBs should be performed by qualified maintenance personnel who have a thorough understanding of AF-400

6-2

UNION SWITCH & SIGNAL e3 System operation and, specifically, the circuit operation of the PCBs that are part of the AF-400 System. They must also be thoroughly experienced in the use and application of the test equipment listed in Table 6-1.

6. 3 .1 'I'roubleshooting Philosophy

In the following subparagraphs, the PCBs, coupling unit and minibond are serviced, adjusted, and/or tested on the bench using appropriate test equipment and bench test setups. These procedures include applicable adjustments and calibration information, since all that may be wrong with a PCB is the need for alignment. If the proper indications are observed when checking the PCB in question, calibration and/or adjustment may be unnecessary. By performing these procedures,

· using the test equipment and normal indications specified at respective test points, maintenance personnel can isolate a fault to a PCB component (transistor, integrated circuit, transformer, etc.) by the logical process of elimination. When the fault has been isolated to a particular component, or group of components on a board, the faulty component(s) is replaced. The PCB is then rechecked for normal operation to make sure the fault has been corrected. As an aid in troubleshooting the PCBs on the bench, it is recommended that standard track circuit card files (19-inch and 5-inch) be used as the PCB mounting base, with card extenders, to facilitate PCB interconnect~ons, when required, and the connection of test equipment.

Although the coupling unit and minibond are non-repairable (since they are encapsulated units), bench test procedures are included for these units as an aid in verifying faulty operation and/or making sure replacement units meet minimum performance standards. Refer to Section IV for schematics of the PCBs, coupling units, and minibond; refer to Appendix A for applicable assembly diagrams and parts list.

6.3.2

a.

b.

Cab Oscillator PCB Troubleshooting (See Figure 6-1.)

Test Equipment Required:

( l) Oscilloscope

( 2 ) Power Supply, 24 Vdc

( 3) Multimeter.

Test Procedure:

(1) Connect 24.0 +1.0 Vdc power supply to pin l (+), and pins 17/18 {-), and apply power to setup.

NOTE

Power supply ripple must not exceed 0.2 Vp-p.

6-3


OSCILLATOR PCB N451054-1302

TP1

990 Hz CAB OSCILLATOR i--------4--<

17/18

+

24 voe POWER SUPPLY

+

OSCILLOSCOPE

Figure 6-1. Cab Oscillator PCB, Test Setup

(2) Using an oscilloscope, verify that output at TPl (yellow) is a 0.73 +0.03 Vrms sine wave, with a frequency of 990 Hz-~0.1%.

(3) Verify that de output voltage at TPl is 13.5 +1.35 Vdc.

6.3.3 Coder/Oscillator PCB Troubleshooting (See Figure 6-2.)

a. Test Equipment Required:

(1) Frequency counter

(2) Oscilloscope

(3) Digital Multimeter (DVM)

(4) Power Supply

(5) Resistor, 6.2K, l/2W

(6) Resistor, 200K, l/2W

(7) Resistor Decade Box (2), 0 to l megohm (R Box).

6-4

UNION SWITCH & SIGNAL ffi b. Test Procedure:

(1) Connect PCB 1~ test setup as shown in Figure 6-2.

(2) Set power supply to 24 +0.2 Vdc before connecting t0 PCB.

(3) Set switch SWl on PCB to center position.

(4) connect an R box in place of R6. Set to 2K ohms.

(5) Connect frequeLcy counter and oscilloscope channel 3 to PCB pin 2. Acjust oscilloscope and frequency counter for ac input.

NOTE

Signal is a sine wave less than 20 Vp-p.

(6) Adjust Ll to obtain proper frequency as follows:

Board Suffix Frequency

-8303

-8304

-8305

-8306

1590 +l Hz

2670 +l Hz

3870 +2 Hz

5190 +2 Hz

NOTE

If oscillator does not function, check capacitors Cl and C4 and transistor Ql for shorts or opens. Check Zener diode Dl for correct ~ener voltage (approxii:uately 10 volts).

(7) connect DVM to PCB pin 2. Set DVM to read ac volts, 20-volt range.

(8) vary R box to obtain a reading of 5.6 +0.2 Vrms.

6-5


DIGITAL MULTIMETER

FREQUENCY COUNTER

CH3

OSCILLOSCOPE

24 VDCPOWER SUPPLY

*CONNECT AS REQUIRED

(-)

(+)

(Cl

(Cl

(-)

(+)

*

*

*

CHANNEL1*

. CHANNEL2*

PIN 1

RESISTOR DECADE BOX

6.2K . vvv 200K . VVv

CODER/OSCILLATOR PCB

18 (COM)

16 (50-50 OUTPUT)

17 (A CODE)

CONNECT} FOR STEP b.(53)(j) c ONLY

9

11

1 (+24 VDC)

RESISTOR DECADE BOX 2

Figure 6-2. Coder/Oscillator PCB, Test Setup

6-6

UNION SWITCH & SIGNAL ffi NOTE

Temporarily install selected SOT resistor using shor~ clip leads before soldering into circ~it. Heat from soldering may cause resistance value to increase slightly; this effect is more noticeable on low-value resistors (under lK).

(9) Solder in place closest standard value l/4W, 5% carbon resistor for R6. Recheck ac voltage on meter. Value of R6 should be between O and lOK ohms.

(10 Connect DVM to TPl and ground; de voltage should be -13.6 +0.5 Vdc. Repeat for TP2. Record on data sheet. Turn off power supply.

(11) Connect jumpers for SOT resistors R43, R44, R45, R46, R48, R50, R52, and R54.

(12) Connect oscilloscope to PCB:

(a) Channel 1 to TP6 (use lOX probe)

(b) Channel 2 to TP5 (use lOX probe)

(c) Channel 3 and frequency counter to PCB pin 16. Set vertical attenuation to lOV/DIV and horizontal sweep to 20 MSEC/DIV. Set counter for de input.

(13) Connect R box 1 in place of series combination of Rl6 and R19.

Connect R box 2 in place of series combination of R22 and R24.

Set both R boxes to 30K.

(14) Jumper PCB pin 2 to pin 10 to select 13.6 Hz code rate. Put switch SWl in center position.

(15) Turn on power supply.

(16) Trigger scope on channel 1 using internal normal trigger mode, de positive level. Adjust scope trigger to obtain a stable display. Signals should be synchronized. (See Figure 6-3.)

(17) When two signals on channel 1 (TP6) and channel 2 (TP5) are synchronized, a 50-50 duty cycle square wave appears on channel 3 from pin 16, as shown in Figure 6-3A; amplitude is approximately 20 Vp-p. When two signals on channels 1 and 2 are not synchronized, square wave

6-7

6-8


10V/DIV

I . 10V/DIV

20 OR 10 MSEC/DIV

SCOPE DISPLAY WITH TWO SIGNALS SYNCHRONIZED AND SQUARE WAVE OUTPUT

IA)

I I '

20 OR 10 MSEC/DIV

SCOPE DISPLAY OF TWO SIGNALS UNSYNCHRONIZED AND NO SQUARE WAVE OUTPUT

(B)

CHANNEL 1 (TP6)

CHANNEL 2 (TP5)

CHANNEL 3 (PIN 16)

I CHANNEL 1 (TP6)

CHANNEL 2 (TP5)

CHANNEL 3 (PIN 16)

Figure 6-3. Code P~te Synchronizing Waveforms

UNION SWITCH & SIGNAL ffi at pin 16 disappears or has a random pattern, as in Figure 6-3B. Ccntinue with step (18) regardless if signals are synch:::-cnized or not~:-

(18) Vary R box 2 (F22 and R24) and determine to nearest lK ohm minimum an~ maximum resistance values which keep signals on TP5 and TP6 synchronized.

(19) Verify maximu~ and miniL~m values for R box 2 by observing that cscilloscope channel 3 signal remains a square wave as =ollows:

(a) Go several kilohms below minimum value, then increase value of R box 2 until square wave signal appears stable as in Figure 6-3A. This determines actual minimum value.

(b) Go several kilohms above maximum value of R box 2, then decrease value of R box 2 until square wave signal appears stable. This determines actual maximum value.

(20) Record minimum and maximum values for R box 2 on data sheet.

(21) Determine resistance value that is half way between minimum and maximum. Use this formula: R min+ R max= center value.

2

Set R box 2 tc center value and temporarily record center value for later use.

NOTE

Read thoroughly and completely all portions of steps (22) through (29) before performing any further adjustments.

(22) While monitoring frequency counter and oscilloscope signal on pin 16, vary R box l to set close to, but not less than, nominal value of all eight code frequencies as listed in Table 6-2, connecting a single individual jumper for each frequency per Table 6-2. When initially adjusting R box 1, concentrate on examining three middle range frequencies of 10.8, 13.6, and 16.8 Hz. R box 1 should be varied in 100 ohm and/or lK ohm steps as required.

NOTE

To increase frequency, decrease value of R box 1.

6-9


JUMPER

2-3 2-4 2-6 2-8 2-10 2-12 2-14 2-15

6-10

Table 6-2. Calibration Range for Code Rates

FREQUENCY PERIOD

SOT NOMINAL R.A.lWE +1% NOMINAL RANGE +1% - -R43 5.0 Hz 4.95 to 5.05 Hz 200 ms 198.0 to 202.0 ms R44 6.6 Hz 6.53 to 6.67 Hz 151.5 ms 150.0 to 153.0 ms R45 8.6 Hz 8.51 to 8.69 Hz 116.3 ms 115.1 to 117.4 ms R46 10.8 Hz 10.69 to 10.91 Hz 92.6 ms 91.67 to 93.53 ms R48 13.6 Hz 13.46 to 13.74 Hz 73.5 ms 72.80 to 74.27 ms R50 16.8 Hz 16.63 to 16.97 Hz 59.5 ms 58.93 to 60.12 ms R52 20.4 Hz 20.20 to 20.60 Hz 49.0 ms 48.51 to 49.49 ms R54 27.5 Hz 27.23 to 27.78 Hz 36.4 ms 36.04 to 36.76 ms

(23) If waveforms on oscilloscope go out of sync when varying R box 1, before correct nominal frequencies are obtained, continue with step (24). If oscilloscope waveforms remain in sync, continue with step (26).

(24) Find value of R difference= R box 1 (old value), minus R box 1 (new value) just before oscilloscope signals lose sync. Note that initial value of R box 1 was 30K. If R box 1 (new) is less than R box 1 (old), reduce value of R box 2 by R difference. If R box 1 (new) is greater than R box 1 (old), increase R box 2 by R difference. Generally, if R box 1 is decreased (or increased) by a fixed amount, then R box 2 should be decreased (or increased) by same amount. Waveforms on oscilloscope must now be in sync; otherwise, values of C8, C9, Rl7, and R21 are out of spec, or UJTs Q6 and Q7 are defective.

(25) Temporarily record old and new values of R box land R box 2 and repeat steps (22) through (24) until all eight codes are equal to or above nominal values listed in Table 6-2.

(26) When a value of R box 1 is found to satisfy step (24), find R difference between final value of R box land original 30K value of R box 1.

(27) Set (or verify) final value of R box 2, so that it has been reduced or increased from its initial center value (step (21) by same R difference value calculated in step (26).

NOTE

Use the instructions contained in step (24) as a guide whether to increase or decrease final R box 2 value from initial center value.


(28) Recheck all eight code frequencies and verify that all coaes are greater or equal to nominal value for each frequency as listed in Table 6-2.

NOTE

If done properly, values of R box 1 and 2 selected should allow one of the values of the frequencies 10.8, 13.6, or 16.8 Hz to be extremely close to the nominal value, and one or more of the remaining codes in the range of 10.8 to 16.8 may be within +1%.

(29) Determine which of eight code rate frequencies is closest to its corresponding nominal value. Select that code and temporarily record its frequency to at least two decimal places.

(30) Select next lower standard value 1/4 watt, 5% carbon composition resistor to replace final value of R box 1. Measure resistor with digital meter to verify that it is less thank box l value. Solder selected resistor in place of Rl~. Temporarily turn off power when soldering.

(31) Reconnect R box 1 in place of Rl6 and vary R box 1 to obtain nominal code frequency determined in step (29).

(32) Select closest standard value 1/4 watt, 5% carbon composition resistor to new value of R box 1.

NOTE

Measure the resistors on a meter to obtain a value that is within 100 ohms of R box value. The selected total value for Rl6 and Rl9 is critical; if in doubt as to the correct value, also select SOT resistors above and below the closest value.

(33) Temporarily connect selected resistor(s) in place of Rl6. (See note in step (8).)

(34) Verify that all eight code frequencies are greater than, or equal to, their corresponding nominal value listed in Table 6-2. Pay particular attention to nominal frequency selected in step (29).

(35) Solder selected resistor in place of Rl6. Record values of Rl6 and Rl9 on data sheet.

6-11


6-12

(36) Verify that closest frequency from step (29) is within +1% tolerance of nominal value as listed under range +1% in Table 6-2.

(37) Replace value of R box 2 with 1/4 watt, 5% carbon resistors (R22 ana R24). Select one large value and one small value that add up to R box value. They need not be measured on meter, and values can be rounded off to nearest standard values as required (within lK).

(38) Temporarily turn off power and solder in two resistors, putting larger value into R24. Record resistor values on data sheet.

(39) Turn power on and check all eight frequencies making sure that no code is less than minimum value as listed under RANGE ~1% heading in Table 6-2.

(40) Turn off power and attach one end of a short jumper lead (8 inches or less) having miniature clip ends to terminal lead of CB near Rl6.

The copper trace running near CB, connecting to R23, is connected to 24 volts. The fuse may blow in the ramaining parts of this step if the clip lead is not properly attached.

(41) Jumper pin 2 to pin 10 per Table 6-2 to select 13.6 Hz code rate. Leave frequency counter and oscilloscope connected to pin 16.

(42) Turn on power. Signal on pin 16 should be a 20 +2Vp-p square wave with a frequency of 13 .6 Hz +1%.

(43) Connect free end of jumper attached to C8 to other end of C8. End of CB near edge of PCB is ground. Signal on scope should now be a steady de voltage of either 20 +2 Vdc or O +2 Vdc.

NOTE

If voltage is greater than 18 volts, LED 1 should be on; if voltage is within 2 volts of ground, LED 1 should be off. If this test fails, check transformers Tl and T2 for proper turns and phase connections.


(44) Remove channel land 2 oscilloscope probes from TPS and TP6. Frequency counter and oscilloscope remain connected to pin 16.

{45) Repeat step (39). If test fails, replace ICl (J15029-0099-4u27B CMOS) and repeat steps (39) through (43). Turn off power supply.

(46) Install a 100 pf mica capacitor (J709144-0061) in space provided for capacitor C7 on PCB. Insulate each lead of capacitor with a 3/16-inch length of Teflon tubing (A774230) or equivalent.

(47) Turn on power supply and retest per steps (39) through (43).

(48) Turn off power and remove jumper from both sides of cs. Leave frequency counter and oscilloscope connected to pin 16. Turn on power supply.

(49) Refer to Table 6-2 to determine value of SOT resistors R43, R44, R45, R46, R48, RSO, R52, and R54. Starting with lowest frequency, connect jumper from PCB pin 2 to 3. If frequency at pin 16 is higher than range permits, then connect an R box in place of R43.

(SO) Adjust R box to obtain nominal frequency given. Select nearest 1/4 W, 5% carbon resistor for R43. Solder re-· sister in place and recheck code frequency; it must -fall within given range ±1% in Table 6-2.

(51) Repeat steps {49 and 50) to determine other seven SOT resistors. Depending on how close Rl6 and Rl9 were determined, one or more of these SOT resistors could be O ohm. No SOT resistor shall exceed l.2K.

(52) Record SOT resistance values used, and record code frequency to nearest 0.01 Hz. Resistors do not have to be put in one at a time, they can be installed all at once after values have been determined.

(53) Set output level as follows:

(a) Jumper PCB pins 2 and 3. Connect DVM to PCB pin 17; adjust to read 2 vrms maximum. Put SWl in TRACK position.

(b) Connect an R box for R59 and set to 100 ohms.

6-13


6-14

NOTE

There are no lugs for SOT resistor R59. One end of R59 connects to end of capacitor C23, located near marking for R37. Other end of R59 connects to positive end of capacitors C27 and Cl6 (which is ground).

(c} Turn on power. Adjust tuning slug in T3 to obtain a peak maximum voltage on meter.

(d) Connect oscilloscope channel 1 to PCB pin 17. Measure de offset in output waveform (dimension B in Figure 6-4). De level should be 5.0 +l Vdc. If it is low, replace IC3 and recheck de-level.

(e) Adjust R box to obtain a reading of 0.50 +0.03 Vac. Value of R59 should be between O and lK ohms.

(f) Temporarily connect closest standard value 1/4 watt, 5% carbon composition resistor in place with clip leads. Recheck the voltage reading.

(g) Turn off power. Solde~ in selected SOT resistor in place of R59.

(h) Turn on power. stei:, (53)(e). reading.

Recheck the voltage reading per Record value of R59 and voltage

(i) Execute TaLle 6-3 and verify output voltages.

NOTE

Steps (53)(j) through (p) apply to -8303 and -8304 boards only.

(j) Execute Table 6-4 and verify output voltages for -8303 and -8304 PCBs only.

(k) Remove jumpers from pins 9 to 11 and pins 2 to 12.

(l) Connect oscilloscope to PCB pin 17. Jumper PCB pins 2 to 10. Set SWl to center position.

(m) Connect an R box for R35 and set to lK ohm.

(n) Vary R box to obtain proper duty cycle or on-time of positive pulse width of output waveform, indicated as A in Figure 6-3 to obtain times given in Table 6-5.

•


..... , ... --/..---.-.t., ~ A ~ ~ i J ~

s ±1v w ~ ~ \ ~ ~ I

B

1 ' ov

Figure 6-4. Train Detection Output Waveform

Table 6-3. Code Rate Select vs. Train Detection Frequency Amplitude

OUTPUT VOLTAGE OUTPUT VOLTAGE JUMPER PCB PINS -8303 AND -8304 -8305 AND -8306

2 to 3 0.50 +0.03 Vac 0.50 +0.03 Vac 2 to 4 0.54 +0.05 Vac 0.51 +0.03 Vac 2 to 6 0.56 +0.05 Vac 0.52 +0.03 Vac 2 to 8 0.59 +0.05 Vac 0.53 +0.03 Vac 2 to 10 0.64 +0.05 Vac 0.55 +0.03 Vac 2 to 12 0.68 +0.05 Vac 0.57 +0.03 Vac 2 to 14 0.74 +0.07 Vac 0.59 +0.05 Vac 2 to 15 0.86 +0.07 Vac 0.62 +0.05 Vac - -Table 6-4. Code Rate Select vs. Train Detection Frequency

Amplitude for 1590 Hz and 2670 Hz Only

JUMPER PCB PINS OUTPUT VOLTAGE

2 to 10 and 9 to 11 0.69 +0.05 Vac 2 to 12 and 9 to 11 0.71 +0.05 Vac

6-15

ffi UNION SWITCH & SIGNAL UNION SWITCH & SIGNAL ffi Table 6-5. Code Rate On-Time for -8303 and -8304 PCBs at

13.6 Ez and 16.8 Hz

JUMPER PCB PIN

2 to 10 2 to 12

-8303 PCB -8304 PCB SOT ON TI.ME (A) ON TIME (A)

R35 36% 26.5 +1.0 msec 47% 34.5 +1.0 msec R38 36% 21.5 +l.O msec 42% 25.0 +1.0 msec - -

(o) Solder in nearest 1/4 W, 5% carbon resistor for R35. Recheck output. Record value of R35.

(p) Repeat steps (53)(m) through (o) for R38. Record value of R38.

6.3.4 Transmitter PCB Troubleshooting

Troubleshooting/testing of the Transmitter PCB consists of checking two channels; namely, the cab signal channel and the train detection channel.

NOTE

Checks relating to the train detection channel cannot be performed for the N451570-1902 PCB which has only a cab signal channel.

6.3.4.l Cab Signal Channel ILitial Phase (See Figure 6-5.)


(1) Counter

(2) Signal Generator

(3) Power Decade Resistor

(4) Power Supply 24 Vdc

(5) Coder/oscillator PCB

(6) Power Transistor PCB

(7) Capacitor, l ufd

(8) Cab Switch (SPST)

(9) Resistor, llK

(10) Resistor, 13K

(ll) Resistor, 3.9K

6-16

°' I ...... -...J

COUNTER " v

I I. T(j) 1µf

SIGNAL GENERATOR

J706813 A CAB IN

I e I • ' ' T °'~--- • 9

3

16

q ~g~ER/OSCI LLA TOR

N451570-8303 -8304 -8305 -8306

18

i-.. 1

1 IK J721258

A 'VVV

> 3.9K ~ 13K S J720764 ~ J735254

I 0

DC :, OFFSET

SWITCH (SPOT) J725681

..... ii

TRAIN DET IN

8

CAB SWITCH (SPST) J725681

16

TRANSMITTER PCB N451570-190X

131 121 111 101 71 6

13 I 12 7 6 10

POWER TRANSISTOR PCB

N451054-9302

"'

14

15

19 18

) 17 5

15

14

Figure 6-5. Transmitter PCB, Test Setup

>

•

(2) !,, ?.r..11

>25W ~ J735519-

0392

HI l(+I

24 voe POWER SUPPLY (3A)

POWER DECADE RESISTOR

c z 0 z ~ =i 0 :I: 2" C'/l i;'i z )> r

~


6-18

(12) Resistor (2), 2.5 Ohm, 25W

(13) DC Offset Switch (SPDT).

b. Test Procedure:

(1) connect PCB in test setup as shown in Figure 6-5.

(2) Before turning on power supply, set switch Sl (CAB COARSE) on Transmitter PCB to position 1. Rotate RS (CAB FINE) and R21 (BIAS) controls fully counterclockwise (CCW). Set DC OFFSET switch in test setup (Figure 6-5) to place 13K, 1/2 watt resistor in circuit.

(3) Turn on power supply and adjust both to 24 +O.l Vdc. Adjust signal generator to 990 +5 Hz at 2 +0.1 Vp-p (0.672 - 0.742 Vrms) output level, but do not connect to transmitter yet. Set power decade resistor to value given in Table 6-6.

(4) Close CAB SWITCH (Figure 6-5) and connect digital multimeter from pin 18 to TP13 on transmitter PCB. Set meter to read de millivolts. Adjust R21 (BIAS) clockwise to obtain 1000 +50 millivolts de.

(5) Connect signal generator output (point A on Figure 6-5) to pin 9 of board being tested. Set switch SWl on Coder/oscillator PCB to CAB position.

(6) connect digital multimeter across transmitter output (TPB, TP9) and set for ac volts. Connect an oscilloscope across same points and observe that output is a sine wave with no obvious distortion. Adjust slug in pot core Tl for maximum output voltage.

(7) Set switch SWl on Coder/Oscillator PCB to TRACK position. Output voltage should drop below 200 millivolts rms. Set SWl to center position. Output voltage should appear as in Figure 6-6.

(8) Rotate RS (CAB FINE) fully CW; output voltage should be approximately 2.5 times its previous level. Rotate RS (CAB FINE) fully CCW.

(9) Step Sl (CAB COARSE) from position 1 to position 2. output voltage should increase by approximately 2.5 times its previous level. Repeat for positions 3, 4, and 5. Each position should increase output by a factor of approximately 2.5 times.


CODE RATE I (5 Hz)

Figure 6-6. Trans~itter PCB Modulation Envelope

(10) With switch Slat position 5, rotate RS (CAB FINE) fully CW to obtain maximum output voltage. Set SWl on Coder/Oscillator PCB to CAB position. Open CAB SWITCH (Figure 6-5). output voltage should decrease to less than 0.1 Vrms.

(11) Turn off power supply. This completes initial test of cab signal channel.

6.3.4.2 Train Detection Channel Initial Phase

a. Test Equipment Required: same as paragraph 6.3.4.l a.

b. Test Procedure:

(1) Before turning on power supply, set switch S2 (TRACK COARSE) to position 1, and set switch SWl on Coder/oscillator PCB to center position. Rotate Rl2 (TRACK FINE) fully ccw. If BIAS control (R21) was set during a check of cab signal channel, then it need not be readjusted. Otherwise, rotate it fully CCW. Position DC OFFSET switch in test setup (Figure 6-5) to place 3.9K, 1/2 watt resistor in circuit. This changes de offset for input signal from 13 Vdc to 6 Vdc.

(2) Turn on power supply and adjust to 24 +0.1 Vdc. Adjust signal generator to train detection frequency (within +5 Hz) per Table 6-6. Adjust its level to 2 +O.l Vp-p (0.672 - 0.742 Vrms), but do not connect to Transmitter PCB yet. Set power decade resistor to value given in Table 6-6.

6-19


Table 6-6. Transmitter PCB Decade Resistance Values vs. Frequency

CAB SIGNAL CHJ.J:U:-.."EL TRAIN DETECTION CHANNEL

SUFFIX FREQUENCY RESISTANCE FREQUENCY RESISTANCE N41570- (Hz) (OH!vJS) (Hz) (OHMS)

1902 1903 1904 1905 1906

990 600 - -990 600 1590 700 990 600 2670 1200 990 600 3870 1700 990 600 5190 2250

(3) If bIAS control (R21) does not require adjustment, then skip to step (4). Otherwise, connect digital multimeter from ~in 18 to TP13 on Transmitter PCB. Set meter to read de millivolts, and adjust R21 (BIAS) CW to obtain 1000 +50 millivolts de.

(4) Connect signal generator output (point A on Figure 6-5) to pin 3 of board being tested. Set switch SWl on Coder/Oscillator PCB to TRACK position.

(5) Connect digital multimeter across transmitter output (TP8, TP9) and set for ac volts. Connect an oscilloscope across same points and observe that output is sine wave with no obvious distortion. Adjust slug in pot core T2 for maximum output voltage.

(6) Set switch SWl on Coder/Oscillator PCB to CAB position. Output voltage should drop below 200 millivolts rms. Set SWl to center position. Output voltage should be coded (modulated), and modulation envelope should appear as in Figure 6-6.

(7) Rotate Rl2 (TRACK FINE) fully CW. Output voltage should be approximately 2.5 times its previous level. Rotate Rl2 (TRACK FINE) fully CCW.

(8) Step switch S2 (TRACK COARSE) from position 1 to position 2. Output voltage should increase by approximately 2.5 times its previous level. Repeat for positions 3, 4, and 5. Each position should increase output by a factor of approximately 2.5 times.

(9) Return switch S2 to position 1. This completes test of train detection channel.

6.3.4.3 Cab Signal and Train Detection Measurements (See Figure 6-5.)

a. Test Equipment Required: same as Paragraph 6.3.4.1 a.

6-20

UNION SWITCH & SIGNAL EB b. Test Procedures:

(1) Connect Transrritter PCB in test setup as shown in Figure 6-5.

(2) Set switches s: and 82 to position 1 and rotate both RS (CAB FINE) and Rl2 (TRACK FINE) fully CCW.

(3) Set signal generator to 990 +5 Hz at 2.0 +0.1 Vp-p (0.672 - 0.742 Vrms). Connect point A of-Figure 6-5 to pin 9 of Transmitter PCB.

(4) Open CAB SWITCH and turn on power supply. Adjust power supply output to 24.0 +0.5 Vdc. Adjust decade resistor to resistance given in-Table 6-6 for cab signal channel. Close CAB SWITCH.

(5) connect signal generator output (point A) to pin 9 of Transmitter PCB. Place switch SWl on Coder/Oscillator PCB in CAB position.

(6) Measure rms ac voltage across decade resistor. This value should fall in range given to switch position 1 in VMIN column under CAB SIGNAL in Table 6-7. Record measured value on test record sheet.

(7) Repeat for positions 2, 3, 4 and 5. Return switch Sl to position 1.

(8) When switch Sl is in position 5, bias voltage must be set to 2.00 +0.05 Vdc. Do this by connecting DVM from pin 18 to TP13 and adjusting BIAS control R21. When switch Sl is in positions 1, 2, 3, and 4, bias should be set at 1.00 +0.05 Vdc.

(9) Adjust R5 (CAB FINE) fully CW (maximum output). Measure rms ac voltage across decade resistor. This value should fall in rcnge given for switch position 1 in VMAX column unde= CAB SIGNAL in Table 6-7. Record measured value on test record sheet. Repeat for positions 2, 3, 4, and 5. Return switch Sl to position 2.

(10) Disconnect point A from pin 9. Adjust to specified train detection frequency (within +5 Hz) from Table 6-6. Adjust output voltage to 2.0-+0.l Vp-p (0.672 -0.742 Vrms), and connect point A to-pin 3. Adjust decade resistor setting to train detection channel. Set SWl on Coder/Oscillator PCB to TRACK position.

(11) Measure ac rms output voltage across decade resistor. This value should fall in range given for switch position 1 in VMIN column under TRAIN DETECTION in Table 6-7. Record this value in appropriate place on test

6-21


record sheet. Repeat for switch positions 2, 3, 4, and 5. Return switch S2 to position 1. ( Check step ( 8) for proper bias adjustment.)

Table 6-7. Acceptable Ranges for AF-400 Transmitter RMS Output Voltage

CAB SIGNAL TRAIN DETECTION SWITCH

POSITION VMAX V.t,'.;IN VMAX VMIN

1 2 3 4 5

1.5 to 6.0 0.5 to 2.2 0.9 to 4.0 0.3 to 1. 7 4 to 15 1.5 to 5.5 2.4 to 10 0.8 to 4.0 13 to 38 4 to 14 6 to 27 2.2 to 10 34 to 92 13 to 36 16 to 60 6 to 27 80 to 149 35 to 88 41 to 140 15 to 65

(12) Adjust Rl2 (TRACK FINE) fully clockwise (maximum output voltage). Measure ac rms output voltage across decade resistor. This value should fall in range given for switch position 1 in VMAX column under TRAIN DETECTION in Table 6-7. Record this value in appropriate place on test record sheet. Repeat for switch position 2, 3, 4, and 5. Return switch S2 to position 1.

(13) Remove Power Transistor PCB from cardfile. With S2 in position 4, adjust Rl2 per Table 6-8 to obtain X Vrms at TP12. The voltage between TP7 (W) and TPlO (BR) should be within the range tabulated in Table 6-8.

Table 6-8. Train Detection Frequency vs. VRMS Modulation Voltage

TRAIN DETEC'IION VOLTAGE BETWEEN (VAC) SET VOLTAGE AT TP12 FREQUENCY TP7 (W) and TPlO (BR) TO -

1590 Hz 0.31 to 0.57 2670 Hz 0.18 to 0.33 3870 Hz 0.11 to 0.20 5190 Hz 0.16 to 0.08

6.3.5 Transmitter Power Transistor PCB Troubleshooting

NOTE

If a different instrument is used than the one specified, erroneous readings may result. Use only the instrument specified for this test.

(VAC)

0.60 +0.03 0.30 +0.02 0.30 +0.02 0.60 +0.03 -

Testing of the Transmitter Power Transistor PCB is accomplished with power off and taking resistance measurements at the PCB connector pins, using a Simpson 260 multimeter. Connect the plus (+) and minus

6-22

UNION SWITCH & SIGNAL ffi (-) leads of multimeter as indicated in Table 6-9. The meter polarity switch must be in the +DC position for all tests. Each time the resistance scale is changed, zero the multimeter by connecting the test leads together and aciji.:st the ZERO OHMS control for zero reading.

Table 6-9. Resistance Measurements on Transmitter Power Transmitter PCB

+ - RESISTANCE ACCEPTABLE RANGE LEAD LEAD SCALE (OHMS)

4, 5 6, 7 Rxl 10 - 20 10, 11 12, 13 I Rxl 10 - 20 6, 7 4, 5 I RxlOOOO 0.5 Meg or higher 12, 13 10, 11 RxlOOOO 0.5 Meg or higher 8, 9 4, 5 I RxlOOOO 100,000 or higher 14, 15 10, 11 RxlOOOO 100,000 or higher 4, 5 8, 9 Rxl 10 - 20 10, 11 14, 15 Rxl 10 - 20

6.3.6 Receiver Input PCB Troubleshooting

The Receiver In~ut PCB tests include bandpass filter alignments and gain calibration and verification.

6.3.6.1 Bandpass Filter Alignment



(2) Frequency counter

(3) AC Voltmeter

(4) Oscilloscope

(5) Power Supply, 24 Vdc

(6) Decade Resistor (O - 1 Meg)

(7) Resistor RTl (Table 6-10).

b. Test Procedure:

(1) connect PCB under test as shown in Figure 6-7 and set RBl to SOK. Ensure that resistor RTl is correct value per Table 6-10. If a wire jumper is installed at JPl, it must be removed.

(2) Turn on power supply and adjust to 24 +l Vdc.

6-23


SUFFIX

-3002 -3003 -3004 -3005

POWER SUPPLY

Table 6-10. RTl Resistor Values vs. Frequency and Filter Input Voltage

VOLTAGE A'r INPUT TO FILTER (VRMS)

NOMINAL TUNING RTl FREQ FREQ ( OHl-'lS) MIN NOM MAX

1590 1580 750 0.950 1.00 1.05 2670 2675 l.3K 0.789 0.830 0.872 3870 3864 2K 0.475 0.500 0.525 5190 5186 2.4K 0.428 0.450 0.473

(3) Set signal generator to tuning frequency (not nominal center frequency) per Table 6-10. Adjust signal generator output level to obtain 1 +0.1 Vrms CW output, as measured on ac voltmeter.

(4) Connect a clip lead from TLl to TL2 on board being tested. Adjust slug in pot core Ll for minimum indication on voltmeter.

(5) Remove clip lead from TLl and TL2. Adjust slug in pot core T2 for a maximum indication on voltmeter.

(+)

(-)

RT1

18

11 RECEIVER INPUT PCB N451570-30XX

SIGNAL GENERATOR 13

FREQUENCY COUNTER

AC RMS VOLTMETER

TLS TL6 TL7 TLB

0- 1 MEG DECADE RESISTOR {RBI)

OSCILLOSCOPE

Figure 6-7. Receiver Input PCB, Test Setup for Bandpass Filter Alignment and Gain Calibration

6-24

UNION SWITCH & SIGNAL EE (6) Solder in a i22 wire jumper (UA43183) at JPl. Connect

a clip lead free TL3 to TL4. Adjust slug in pot core L2 for a mini~uc indication on ac voltmeter.

(7) Remove clip lead from TL3 and TL4. Adjust slug in pot core T3 for a ~aximum indication. At this point, indication may become difficult to identify.

(8) Adjust signal senerator output level to obtain 0.2 +0.02 Vrms on ac voltmeter. Connect voltmeter to TLS and TL4 (commc~). carefully adjust slug in pot core T3 for a maxicuc indication.

(9) Connect voltmeter to TL9 and TL4 (common). Adjust slug in pot core T4 for a maximum indication. This maximum is quite broad and uncritical.

(10) carefully seal slugs in pot cores Ll, L2, Tl, T2, and T3 with RTV (U~41652). Ensure that slugs are not rotatea during application.

6.3.6.2 Gain Calibration

a. Test Equi~ment Req~ired: Same as paragraph 6.3.6.la.

c. Test Procedure:

(1) Connect PCB under test as shown in Figure 6-7. Set RBl to SOK. 'Iurn on power supply and adjust to 24 +l Vdc. Ensure that value of RTl is correct per Table-6-10.

(2) Set signal generator for continuous wave (Cw) output at nominal frequency +2 Hz per Table 6-10. Adjust generator output leveT to obtain value in column of Table 6-10 labeled VOLTAGE AT INPUT TO FILTER (Vrms). Voltage must be between MIN and MAX values given.

(3) Set signal generator for gated output with a 5 +0.5 Hz code rate. Connect oscilloscope to trigger from gating signal (auxiliary output) to facilitate measurement and obtain a stable display.

(4) Reduce value of RBl step-by-step and observe that peakto-peak level of square wave on oscilloscope increases. Adjust RBl and find value which produces a peak-to-peak voltage of 14 +lV. Solder in next lowest value 1/4 watt, 5% carboc resistor for RS.

(5) Connect resistor decade box in place of R9. Adjust resistance value to obtain an output voltage of 14 +0.5 Vp-p for square wave. Solder in closest value 1/4 -

6-25

(33 UNION SWITCH & SIGNAL

watt, 5% carbon resistor for R9. Total resistance (R8 and R9) should be between 0.2K and SOK ohms. Record values of RB and R9 which were installed.

6.3.6.3 Bandpass Filter Check


( 1 ) Counter

(2) Spectrum Analyzer

( 3 ) Amplifier

(4) AC Voltmeter

( 5) Power Supply, 24 Vdc

(6) Resistor RTl (Table 6-10).

b. Test Procedure:

(1) Connect board under test as shown in Figure 6-8. Value of RTl is given in Table 6-10.

(2) Turn on power supply and adjust to 24 +l Vdc.

24VOC COUNTER - AC VOLTMETER n POWER SUPPLY

-(D .......

(-) (+)

(~ ()-18 1

SPECTRUM u RT1 • 13 RECEIVER INPUT AMPLIFIER ,-.... ...._..._A ~

ANALYZER LJ ... T PCB , . 11

(TABLE 6-10) N451570-30XX

(LO) (HI) TL5 TL4 (CDMI

j j'

Figure 6-8. Receiver Input PCB, Bandpass Filter Check Test Setup

6-26

UNION SWITCH & SIGNAL ffi (3) Adjust spectru~ analyzer for 1 dB/division vertically,

and set frequen=y to obtain tuning frequency +2 Hz per Table 6-10 at center of screen. Horizontal display should be set fer 10 Hz/aivision.

(4) Adjust filter i~put voltage as measured on voltmeter in accordance with Table 6-10.

(5) Check that total 3 dB bandwidth is 60 +5 Hz. Record actual bandwid~~.

(6) Set vertical display for 10 dB/division and horizontal display for 50 Ez/division.

(7) Check that total -30 dB bandwidth does not exceed 225 Hz. Record actual bandwidth.

(8) Set horizontal display for 100 Hz/division.

(9) Check that total -60 dB bandwidth does not exceed 550 Hz. Record actual value.

6.3.6.4 Gain Verification

a. Test Equipment Required: same as paragraph 6.3.6.la.

b. Test Procedure:

(1) Connect the board under test as shown in Figure 6-7, except do not connect decade resistor box (RBl). Refer to Table 6-10 fer proper RTl values.

(2) Turn on power supply and adjust for 24 +l Vdc.

(3) Set signal generator to nominal frequency +2 Hz per Table 6-10.

(4) Set signal generator for gated output at a 5 +0.5 Hz code rate.

(5) Reduce signal generator output level to minimum. Slowly increase level to obtain a 14 +O.~V peak-topeak square wave on oscilloscope.

(6) Set signal generator for continuous output (without disturbing output level). Voltage indicated on voltmeter should correspond with column in Table 6-10 labeled VOLTAGE AT INPUT TO FILTER (Vrms). This voltage must be between MIN and MAX values given.

(7) Record actual values measured.

6-27


6.3.7 Receiver Synchronous Rectifier PCB Troubleshooting

The Receiver Synchronous Rectifier PCB tests include the time delay circuit test, synchronous rectifier and level detector test, ana response time test.

NOTE

For proper operation of this board, it must be oriented vertically; that is, the arrow on the case of RLYl must point up. Normal board orientation is achieved when the boara is properly positioned in the card file or on an extender board, with the card file positioned as it would normally be in the equipment cabinet.

6.3.7.1 Preliminary Steps

a. Rotate potentiometers R23 and R25 fully counterclockwise ( CCW).

b. Connect a jumper between TP4 and TP7. Connect a second jumper between TP2 and TP6. Using an ohmmeter, de resistance between TP2 and TP4 must be greater than 20 megohms. Remove two jumpers.

6.3.7.2 Time Delay Circuit Test

6-28


(1) Coder/Oscillator PCB

(2) Oscilloscope

(3) Power Supply, 24 Vdc.

b. Test Procedure:

( l) Connect board under test into test setup of Figure 6-9. Turn on power supply and adjust to 24 +lV output.

(2) Verify that voltage between TPl and TP6 is 24 +l Vdc. Verify that voltage between TP2 and TP6 is 12 +0.6 Vdc.

(3) Select a 5 Hz code rate by connecting a jumper from pin 2 to pin 3 on Coder/Oscillator PCB. Each code rate can be selected by connecting a jumper from pin 2 to the appropriate pin as shown in Figure 6-9.

(4) Set oscilloscope for triggering on a negative(-) slope from an external trigger source. Connect scope trigger input to pin 13. Connect vertical input probe to TL4 and common. Display should show a delayed rising edge as shown in Figure 6-lO(A).

3


24 voe POWER SUPPLY

(+) I{-)

CODER/OSCILLATOR PCB 1 1 RECEIVER SYNCHRONOUS

N451570-8303 RECTIFIER PCB (1590 Hz}

18 l 18

)

5.0

-16

,J 13

N451570-2901

2 • 16

-~( D-

4 6 8 10 12 14 15 . t, I- -x a:

t(" JUMPER wt: ) :> ) :> ) ) )

6.6 8.6 10.8 13.6 16.8 20.4 27.5

0

t OSCILLOSCOPE

Figure 6-9. Receiver Synchronous Rectifier PCB, Test Setup

MIN

4.1

(5) ~ith R23 fully CCW, delay time TD should be in range indicated in Table 6-11. Record time delay. Note that delay times are given in milliseconds.

(6) Rotate R23 fully clockwise (CW). Delay time must again be in range inaicated in Table 6-11. Record time delay. Rotate R23 fully CCW again.

(7) Set oscilloscope to trigger from a positive(+) slope from an external trigger source. Display should show a delayed falling edge as in Figure 6-lO(B). Repeat steps (5) and (6), but rotating R25 instead of R23. Record results.

Table 6-11. Code Rate Delay Time Adjustment

FULLY CCW FULLY CW ( DELAYED TI!v'JE - msec) (DELAYED TIME - msec)

NOM MAX MIN NOM MAX

5.1 6.8 43 55 70

6-29


24V 24V

If\ \V

0 ov

~ TD ~ ~ TD ~ ADJUST R23 ADJUST R25

(A) (B)

Figure 6-10. Code Rate Delayed Rising and Falling Edge Timing

6.3.7.3 Synchronous Rectifier and Level Detector Test. This test requires a setup simulating a complete transmitter and receiver. A card file (N451082-1001) shoulc be configured with the PCBs listed in paragraph a.

6-30

a. Test Equipment Required: (See -Figure 6-21.)

(1) Card File (N451082-1001)

(2) Transmitter PCB (N451570-1903), 1590 Hz

(3) Power Transistor PCB (N451054-9302)

(4) Coder/oscillator PCB (N451570-8303)

(5) Receiver Input PCB (N451570-3002), 1590 Hz

(6) Extender Card (2)


(8) Track Relay and Mounting Base

(9) Resistor RTl

(10) Resistor RT2

(11) Oscilloscope

(12) Digital Multimeter

(13) Decade Resistance Box (O - lOK).

UNION SWITCH & SIGNAL tB b. Test Procedure:

(1) Make connections to card file as shown in Figure 6-11.

(2) Turn on power supply and adjust to 24 +l Vdc. Connect DVI-:: to TP13 and pin 18 on Transmitter PCB. Adjust bias control (R21) to obtain a reading of 1.0 Vdc on DVM. Using TRACK COARSE and TRACK FINE adjustments on Transmitter PCB, adjust transmitter output to obtain an 18 V_I:J-p signal across TP3 and TP2 (common) of PCB under test.

(3) Connect digital voltmeter across TLl (+) and TL2 (-). Select a 16.8 Hz code rate on Coder/Oscillator PCB. Turn adjustment slug in T2 fully clockwise (full-in).

(4) Adjust R23 ana R25 to obtain a maximum de level.

(5) Keep digital de voltmeter across TLl (+) and TL2 (-). Using TRACK FINE adjustment on Transmitter PCB, find point at which track relay just energizes. This procedure must be done slowly to allow for time delays in circuit, and must be repeated until pick-up point is located. DC voltage across TLl and TL2 must be between 5.40 and 6.30 volts. If vo~tage is greater than 6.30, replace D3. D3 is a Zener diode type LVA450, 5.0 volt (J726150-0093) for reference. Record value of voltage.

(6) Using TRACK FINE adjustment on transmitter PCB, adjust level until de voltage across TLl and TL2 is O.SV below pick-up point.

(7) set decade resistor box to its maximum value and connect it between TLl and banded end of D3. Slowly reduce decade resistance value until track relay just energizes. Decade resistance value must be less than, or equal to, 3K ohms. Disconnect decade box. Record decade resistance value.

(8) Connect de voltmeter across TP5 (Y) and TP6 (BR). Increase output of Tranmitter PCB by using TRACK FINE adjustment until TR relay just picks, and LED 1 on N451570-2901 PCB is on continuously without blinking off. DC voltage must be greater than 0.58V.

6-31


N ~ a: 0 ... cc I-

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

----0 RT1

3K,'Z,'i - A ... """ l c 0

0

0

0 RT2 >

0 1K > 11zw;>

0

0

0

0

:J -... --0

0

0

0

0

0

0

0

0

0

c --':... -

--330..,_ ____________ ___,

34 II.JO-------------. I ·A I +A

I I TRACK RELAY N322500-901 W/MOUNTING BASE N334266

(+)

24 VDC POWER SUPPLY

(-)

Figure 6-11. Card File Connections for Level Detector Test

6-32

UNION SWITCH & SIGNAL ES 6.3.7.4 Synchronous Rectifier Response Time Test

a. Test Equipment Req~ired:

( 1) Same as paragrc.ph 6.3.7.3

( 2) Resistor RT3

( 3) Switch STl ( SP ST)

( 4) switch ST2 (SPST)

( 5 ) Diode, IN4003

( 6) Resistor RT4

( 7 ) Resistor RT5

(8) Resistor RT6

( 9) KR Relay.

b. Test Procedure:

(1) Connect test circuit in Figure 6-12. Turn on power supply and adj~st for 24 +l Vdc. Select a 16.8 Hz code rate on Coder/Oscillator PCB. Press pushbutton switch ST2. Set SWl on Coder/Oscillator PCB in center position. connect a DVM to TLl and TL2 on PCB under test. Adjust transmitter output level to obtain a reading of 6.8 +0.1 Vdc. Change the code rate to 5 Hz on Coder/ Oscillator PCE. Voltage should be greater than 6.5 Vdc. (If voltage is not greater than 6.5 Vdc, then transformer Tl is faulty.) Set SWl on Coder/Oscillator PCB in TRACK position. Connect DVM to TP13 and pin 18 on Transmitter PCB. Adjust bias control (R21) to obtain a reading of 1.0 Vdc on DVM. Place SWl on Coder/ Oscillator PCB to center position.

(2) Using TRACK FINE adjustment, find transmitter level at which track relay just picks. Set SWl on Coder/Oscillator PCB in TFACK position. Connect DVM across RTl and measure rms value of ac voltage. Adjust TRACK FINE (and TRACK COARSE if necessary) to increase ac voltage by 50% (just multiply by 1.5). Set SWl on Coder/Oscillator PCB to center position; track relay should pick up.

(3) Connect storage oscilloscope vertical input as shown in Figure 6-12. Adjust for 5 volts/division de vertical deflection. connect external trigger terminal of oscilloscope as shown in Figure 6-12. Select a 5 Hz code rate on Coder/Oscillator PCB. Set oscilloscope

6-33


2

30

4

5

60

70

so 90

RT2 10 O 1K

11 0 1/2W

12 0

13 0

14 0

15:=J 16

17

18

19 0

20 0

21 0

22 0

23 0

24 0

25 0

26 0

27 0

280

29

30

31

32

33

34

RT1 3K,-:NV

RT3 1K -:NV

6 KR

10

(+)

24 voe POWER SUPPLY

5

RT4 10K 1/-:NV

(COM)

_J_ ST1 (SPST) J725326)J725750

SCOPE TRIG

ST2 (SPST) 11 DT1, 1N4003

MPA-1038 KR

--tl_~ 7

(J723555)

+

KR

J726108

1F

1H TR RT5 10K 1/-:NV

+A

TRACK RELAY N32250~901

___ ... W/MOUNTING BASE TR N334266

OSCILLOSCOPE

18 ... ----~..----i~I VERT INPUT

RT6 10K, 1/'Z-IV

Figure 6-12. Card File Connections for Response Time Test

6-34

UNION SWITCH & SIGNA:.. EE for external pcsitive de triggering, and for storage mode operation. Temporarily set oscilloscope for internal trigge= and carefully justify sweep to left edge of calib=ated horizontal scale. Return to external trigger and set sweep width for 100 milliseconds/division.

(4) Pressing pushb~tton switch STl should drop TR relay and generate a single stored trace as shown in Figure 6-13. If osci:loscope does not trigger, it may be necessary to acjust trigger sensitivity. Reset test circuit by pressing pushbutton ST2. TR relay will pick after a delay of approximately 1.4 seconds.

(5) Repeat step (4), erasing stored image as necessary, until oscilloscope reliably triggers each time STl is pressed.

(6) Erase any stored image and press STl, dropping TR relay. Observe stored image and determine times Tl and T2 as indicated in Figure 6-13. Tl should be less than 520 milliseconds and T2 should be less than 620 milliseconds. Reset circuit by pressing ST2.

(7) Repeat step (6) at least ten times for each Receiver Inp~t PCh, an~ ensure that it meets timing criteria each time. Record maximum times for Tl and T2 from this series.

(8) Set oscillosco?e for negative external de triggering and adjust sweep width for 0.2 second/division. P=ess STl to drop TR relay. Pressing ST2 should generate a single stored trace as illustrated in Figure 6-14. If scope does not trigger, it may be necessary to adjust trigger sensitivity. Reset test circuit by pressing pushbutton STl, picking TR relay.

(9) Repeat step (E), erasing stored image as necessary, until oscilloscope triggers reliably each time ST2 is pressed.

(10) Erase any stored image, and press ST2, picking TR relay. Observe stored image and determine time T3 as incticated in Figure 6-14. Time T3 should be between 1.0 second and 1.50 seconds. Reset circuit by pressing STl.

(11) Repeat step (10) at least three times for each Receiver Input PCB, and ensure that it meets timing criteria each time. Record maximum and minimum time found for T3 from this series.

6-35


5 VOL TS/ 25 1---1--+--........ -+---+--r--+--+--+---I DIVISION

Figure 6-13.

Figure 6-14.

6-36

TIME T2

12V p,,111-----..--t-..-TIMET1

o,__ _____ _..._._ _______ ___.

0 500 100 MILLISECONDS/

DIVISION

1000

Stored Oscilloscope Display for Determining Track Relay Response Times Tl and T2

5 VOLTS/

DIVISION 25 1---+--+--+--+---+--+--+--+--+--I 24V P"II .... -..-.... -..-..... -.

0

TIMET3

-------i12v

1.0

0.20 MILLISECONDS/ DIVISION

Stored Oscilloscope Display for Determining Track Relay Response Time T3

UNION SWITCH & SIGNAL 83 6.3.8 Line Transmitter/Receiver PCB Troubleshooting

Except for ac breakdown test, the transmitter and receiver sectio~s of this PCB are tested independently.

6.3.8.1 AC Breakdown Test


AC Hi-Pot Tester.

b. Test Procedure:

I WARNING -

HAZARDOUS VOLTAGE IS USED IN THIS TEST. USE EXTREME CAUTION WHEN ADJUSTING HI-POT TESTER OUTPUT.

(1) Make sure hi-pot tester is turned off, and connect PCB under test as shown in Figure 6-15.

3 LINE TRANSMITTER/ RECEIVER PCB

1

8 N451570·3101 6

9 14

16 18

11

12

I I AC HI-POT TESTER

Figure 6-15. Line Transmitter/Receiver PCB, AC Breakdown Test setup

6-37


(2) Adjust current trip limit of hi-pot tester for 0.3 milliampere.

(3) Turn on hi-pot tester and adjust for 1000 Vac (60 Hz).

(4) At end of one min~te, ac leakage shall not exceed 0.3 milliampere limit.

6.3.8.2 Transmitter Section Test

6-38

a. Test Equipment Requirec:

{l) Power Supply, 24 Vdc



(4) Resistor, 150 OhE.

b. Test Procedure:

(1) connect boaro under test as shown in Figure 6-16.

24 voe (+}

POWER SUPPLY NO. 1 (-}

1s voe (+}

POWER SUPPLY N0.2 (-)

(COM) SIGNAL -----1 t GENERATOR

/""'\ \..../

1

18

3

16

6

LINE TRANSMITTER/ RECEIVER PCB N451570-3101

8

D 1so n, %W,5% J721248

Figure 6-16. TransEitter Section, Test Setup

(2) Turn on power supply #1 and adjust its output to 24 +0.5 Vdc.

(3) Turn on power supply #2 and adjust to 15 +0.5 Vdc.

UNION SWITCH & SIGNAL ffi (4) Set signal generator to obtain a square wave at 20 +2

Hz, with a peak-to-peak level of 20 +2V.

(5) LEDl on edge of PCB should be flashing at signal generator output frequency.

(6) Connect oscilloscope across load resistor connected to pins 8 and 9.

(7) Peak-to-peak vcltage at this point must be between 6.6 and 8.8 volts. This voltage must be measured differentially.

(8) Record this value.

( 9) 'l'hi s completes testing of transmitter section.

6.3.8.3 Receiver Section Test




(3) Digital Multimeter.

b. Test Procedure:

(1) Connect board under test as shown in Figure 6-17.

(2) Turn on power supply #1 and adjust to 24 +0.5 Vdc.

(3) Make sure multimeter is set for de current measurement, on 20 mA full-scale range.

(4) Temporarily disconnect positive lead from power supply #2. Turn it on and adjust for 20V +2V. Set output current for minimum and reconnect positive lead to power supply.

( 5) -using current adjust on power supply #2, gradually increase current until LED2 just goes dark. This value is designated upper trip current, and should be between 8 and 16 m.A.

(6) Gradually reduce current until LED2 just turns on. This value is designated lower trip current, and should be between 4 and 8 mA.

(7) Record upper trip current and lower trip current.

(8) This completes testing of receiver section.

6-39


LINE

(+) 1 TRANSMITTER/

24 VDC RECEIVER PCB POWER

(-) 18 N451570-3101

SUPPLY (::1)

20 VDC (-) 11

POWER (+)

SUPPLY (=2) 12

(+) (-)

DIGITAL DC MILLIAMMETER

Figure 6-17. Receiver Section, Test Setup

6.3.9 Berthing Timer PCB Troubleshooting

6-40


(l) Power Supply, 24 Vdc

(2) Resistor, 360 Ohms (2).

b. Test Procedure:

(1) Connect PCB in test setup as shown in Figure 6-18. Adjust power supply to 24.0 +0.l Vdc.

(2) connect storage oscilloscope to pin 3. Waveform should appear as in Figure 6-19. Measure On-time and offtime using 0.2 sec/division scale, and record these values. These times must agree with values given in Table 6-12. Waveform amplitude should be 23.8 +0.2 Vp-p. Record voltage.

(3) Move oscilloscope to pin 11 and repeat measurements in step (2).

(4) This completes testing of the Berthing Timer PCB.

~ UNION SWITCH & SIGNAL ti,

BERTHING TIMER P:S N451570-18XX

18 11 9

360 :1, ~ 1W J723745

24 voe POWER SUPPLY

Figure 6-18. Berthing Timer PCB, Test Setup

I I I ,-.

ON TIME OFF TIME

I ....

--f 23.SV ±o .2V

+

Figure 6-19. Ber~hing Timer output Waveform

Table 6-12. Berthing Timer On-Off Time Measurement

ON TI.M.E (SEC) OFF TIME (SEC)

SUFFIX MIN }:AX MIN MAX

-1801 0.67 0.75 1.35 1.50 -1802 0.47 0.52 0.47 0.52

6-41


6.3.10 Tuning Panel Troubleshooting

Each decade capacitor circuit on the Tuning Panel PCB is tested in the same manner. Record test results.

a. 'I'est Equipment Required:

RLC Bridge.

b. Test Procedure:

(1) Rotate both FINE and COARSE switches to their fully counterclockwise positions. This.is position 1. Fully clockwise is position 11.

(2) With both switches at position 1, connect RLC bridge to terminals 1 and 2 of terminal board (TBl or TB2). Set bridge for capacitance measurement at lkHz and note residual capacitance from test leads. This must be less than 50 pf. If greater than this, shorter leads must be used.

(3) Rotate the FINE switch step-by-step to position 11. At each step, record capacitance and dissipation factor.

(4) Rotate FINE switch to position land repeat step (3) for COARSE switch.

(5) Any capacitors which are out of tolerance with respect to values in Table 6-13 must be replaced, and electrical test must be repeated in its entirety for that circuit.

(6) Repeat steps (2) through (5) for other circuit on board.

6.3.11 coupling Unit Troubleshooting

The following procedure presents a method of testing the three-frequency coupling units used in the AF-400 System. These coupling units bear part number N451052-32XX and N451052-34XX, and are com-patible only with minibond part number N451003-0701. If a test of the coupling unit reveals a malfunction, the coupling unit must be replaced; it cannot be repaired except for the PCB on which its surge suppressor is mounted.

All coupling units must pass two types of electrical tests. The first is for high potential breakdown between the internal components and case, and for low potential leakage, internally. The second test verifies the intended performance of the internal tuned circuits. Failure to pass either test within specified limits is cause for rejection.

6-42


Table 6-13. Tuning Panel PCB Capacitance and Dissipation Factor Measurements

MINIMUM

I .MAXIMUM t-1,.n.X I MUM

POS. CAP (pf) CAP (pf) DISS. FACTOR

FINE SWI7CH

1 -- 50 0.1 2 950 1050 0.05 3 1900 2100 0.05 4 2850 3150 0.05 5 3800 4200 0.05 6 4750 5250 0.05 7 5700 6300 0.05 8 6650 7350 0.05 9 7600 8400 0.05 10 8550 9450 0.05 11 9500 10500 0.05

MINIMUM MAXIMUM MAXIMUM POS. CAP (uf) CAP (uf) DISS. FACTOR

COARSE SWITCH

l -- 50 pf 0.1 2 0.0095 0.0105 0.05 3 0.0190 0.0210 0.05 4 0.0285 0.0315 0.05 5 0.0380 0.0420 0.05 6 0.0475 0.0525 0.05 7 0.0570 0.0630 0.05 8 0.0665 0.0735 0.05 9 0.0760 0.0840 0.05 10 0.0855 0.0945 0.05 11 0.095 0.1050 0.05

6.3.11.l Leakage and Breakdown Test


(1) Jumper Lead

(2) Hi-Pot Tester.

b. Test Procedure:

WARNING I HAZARDOUS VOLTAGE IS USED IN THIS TEST. USE EXTPLME CAUTION WHEN ADJUSTING HI-POT TESTER OUTPUT.

( % )

( % )

6-43

EE) UNION SWITCH & SIGNAL

(1) If coupling unit is already mounted to a minibond, a1sconnect three-conductor cable from minibond and twist closed ends of cable wires together.

(2) connect a jumper between two ARR terminals at input of coupling unit.

(3) Connect leads of AR 404 hi-pot tester between jumpered AAR terminals and metal case of coupling unit. If necessary, remove a small amount of paint near a bolt-hole in case to obtain a secure electrical connection.

(4) Turn on high-pot tester adjust to 3000 +100 Vac at 60 Hz.

(5) After one minute, leakage current shall not exceed 1 milliampere rms.

6.3.11.2 Performance Test

6-44



(2) Amplifier

(3) AC Voltmenter (2)

(4) Oscilloscope

(5) current Probe

(6) Tuning Panel PCB (N451522-8901)

(7) Minibond (N451003-0701)

( 8) C-Meter.

b. Test Procedure:

(1) Connect coupling unit into test setup shown in Figure 6-20.

NOTE

The minibond may be either a standard unit reserved for tests, or one to which the coupling unit is already mounted.

SIGNAL GENERATOR

AMPLIFIER

IUSE 600 n OUTPUT TAP)

AC VOLTMETER

OSCILLOSCOPE TEKTRONIX

X10 P?.OBE (Cl IC,

___ __.

CURRENT PROBE

AC VOLTMETER


1-.0----~ C4

IWI

OUT

IBI

Bo----~

TBI- ,-----, TB1-

5AIC IWI COUPLING 1------1 MINIBONO

SB

TUNING UNIT PCB N451522· 8901

UNIT (Bl N451Q03. l->-----1 0701

ro-1 l_Q_:J

-32XX

COUPLING UNIT AAR TERMINAL LOCATIONS

CABLE

-34XX

Figure 6-20. Coupling Unit, Performance Test Setup

(2) Adjust frequency of signal generator to highest of three tuned frequencies within +5 Hz, and increase amplifier output slightly. Adjust decade capacitor switches (FINE 1 and COARSE 1) for minimum current. Adjust amplifier output level as necessary to keep voltage at 100 Vrms or less.

NOTE

In following steps, use oscilloscope to make sure that waveform of applied voltage is sinusoidal, without appreciable distortion.

(3) Adjust frequency to 990 +5 Hz and amplifier output to 125 +5 Vrms. Record current. Repeat for all other tunea frequencies (+5 Hz) at 125 +5 Vrms, but without changing decade capacitor setting:

(4) Adjust frequency to 990 +5 Hz and level to 10 +0.5 Vrms. Do not change decade capacitor setting. Record current. Repeat for all other tuned frequencies ±5 Hz at 10 +0.5 Vrms.

6-45


(5) currents measured must be within ranges listed in Table 6-14.

(6) For -34XX coupling units, check value of capacitor C4 with c-meter and verify that its value is within +2% of value shown on assembly drawing parts list (Appendix A). Connect C-meter between terminals A and C as shown on Figure 6-20 with all other equipment disconnected. For -3405 coupling units, value of C4 should be less than 200 pf.

6.3.12 Minibond Unit Troubleshooting

6-46


(1) Impedance Bridge

(2) Power Supply

(3) DC Ammeter (Multimeter)

(4) Digital Voltmeter (Multimeter)

(5) Hi-Pot Tester.

b. Test Procedure:

I WARNING '

HAZARDOUS VOLTAGE IS USED IN THIS TEST. USE EXTREME CAUTION WHEN ADJUSTING HI-POT TESTER OUTPUT.

{l) connect minibond in test setup of Figure 6-21.

{2) Apply 1000 +10 Ez at 1 +0.01 volt to terminals Sl and 82 measure parallel inductance (high Q) and quality factor of coil. Inductance shall be 12.4 +0.1 mH. Quality factor shall be 22 ±2·

-(3) Short terminals Sl and 82 together. Apply a 3000 Vac breakdown test between Sl and case.

(4) Connect minibond in test setup of Figure 6-22. Note that leads from power supply and ammeter must be connected separately from leads of voltmeter. All connections must be made at ends of Pl and P2.

(5) Apply 20 amps de to bond and observe voltage. Voltage shall be less than 0.0005 volt.

Table 6-14. Coupling Unit Current Ranges vs. Frequency

990Hz 1590 Hz 2670 Hz 3870 Hz 5190 Hz

SUFFIX lOV 125V lOV 125V lOV 125V lOV 125V lOV 125V

-3201 8.07 - 9.86 100 - 122 6.56 - 11.1 116 - 211 5.30 - 7.84 66.0 - 110 -- -- -- ---3401 !

-3405

-3202 7.39 - 9.03 97 .4 - 119 -- -- 4.40 - 6.63 64.0 - 80.7 2.98 - 6.92 46.0 - 66.9 -- ---3402

-3203 6.88 - 8.41 94.1 - 115 -- -- -- -- 2.95 - 3.99 54.8 - 73.0 2.54 - 4.66 41.0 'I 59.1 -3403

-3204 9.28 - 12.6 118 - 148 7.27 - 10.3 124 - 160 -- -- -- -- 2.00 - 2.91 33.0 - 45.9 -3404

Note,

a. All Currents in mA.

b. Measured values of current must lie in rangen indicated.

c 2 0 z

~ :j 0 I Ill> (/)

i5 z )>

(j\ ,-I

ffi .f:,. -..J


HIGH S1

IMPEDANCE COIL

BRIDGE GR1608A S2

LOW

Figure 6-21. Minibond Inductance and Quality Factor Test Setup

DC POWER SUPPLY

DC AMMETER ~20A

DIGITAL DC VOLTMETER V

MINIBOND

CT

CT

Figure 6-22. Minibond Impedance Test Set

6.4 COMPONENT REPLACEMENT NOTES

Repair of the AF-400 PCBs consists -primarily of replacing board components which have been found to be defective through the troubleshooting process. Observe the following procedure when replacing components:

6-48

a. Always use a heat-sink, such as needle-nose pliers or alligator clips on the leads of the component to be removed/replaced to prevent cclliponent damage.

b. Use a low-wattage sc~aering iron (60 watts maximum) with pencil ti~ for unsoldering component leads.

UNION SWITCH & SIGNAL m c. Scrape away spraycoa~ from around component and leads pr:or

to unsoldering component.

d. After component replacement, apply spray or brush coat of CONA.P CI:.-1163 Polyi..:rethane (or equivalent) to repaired area.

6. 5 PRE-SHIP.MENT INSPECTION PROCEDURES

Upon comFletion of any mainte::-.ance to the AF-400 PCBs, PCB inspection shoula be performed as follows:

a. All components and material must agree with bill of material and must be correctly installed in accordance with assembly drawings. (Refer to Appendix A.)

b. All devices with polarity indicated must agree with markings on circuit board. Tr.is includes diodes, electrolytic capacitors, transistors and res. Diode polarity is indicated by a band at its cathode, electrolytic capacitors by a"+" symbol, and transistors and ICs by respective arrangement of their lead wires and orientation notch or symbol.

c. All solder connections must be bright and free of flux. A dull, wrinkled appearance indicates a cold solder joint.

d. Transformers connected to circuit board with wires must agree with color code or numbering system, where appropriate.

e. All PCBs must be identified as to circuit board nomenclature, part number, and serial number; all identification must be correct and legible.

f. All mechanical fasteners, such as machine screws and nuts, must be secure and assembled in proper sequence according to drawings (Appendix J..).

g. All PCB jumper wiring should conform to circuit diagram for color code, and all ~ires should be free of abrasions and nicks in their insulation.

6-49/6-50

CODE RATE flUEflENCE [i:y--·-------- ·

INPUT

RX INPUT

RX INPUT

B24-R

II

13

RECEIVER INPUT

N451570-30XX

13

1--'-7 ________________________________ ,_4

RECEIVER SYNCHRONOUS

RECTIFIER N451570-2901

•JNION SWITCH & SIGNAL ffi

15 REL t- Y-

N24-R

10 1124-T THROUGH CAB

17

STA 6( 7 >

--------------. ____ --, .. -_,_-_-___ -__ -__ -_---~~=:~-----_--_--_--_--_---_,.,_T-~-8-(T lflL_}----------------------------~ RELAY'

TURN-ON RELAY~------------------------------·---CONTACT

CAB OSC INPUT

14 >----------------------------------------1------------------.-----~

N24-0

624-0

CODE RATE

SELECT LlNES

CODE RATE REFERENCE OUTPUT

18

17

5.0HZ

6.6HZ

8.6 HZ

I0.8HZ

f 3.6HZ

16. 8HZ

20. 4 HZ

UNUSED OR

JUMPER

8

3

3 18

4 16

6

8 CODER I OSCILLATOR 10 N451570-83XX

12 17 14

15 STA 3(91

2 27.5HZ

14 4 TX OUfl'IJI TRt-NSMI TTER

N451570-190X 15 ------------------------~ TX OUll'III

I 2

8

__ __, 11 STA

2( 11 l 5

13 12 11 10 7 6

13 I? 7 f; 10

POWER TRANSISTORS

N451054-9302

STA I< 12 l

8

9 R3-(R4 l 2.5 OHMS

14 15

RI -( R2 l 2,5 OHMS

-~""---> 8,'4 I

WARNING:

THIS IS A VITAL SAFETY CIRCUIT. ANY CIRCUIT CHANGE OR SUBSTITUTION CAN COMPROMISE THE SAFE PERFORMANCE OF THIS CIR· CUIT. ALL COMPONENTS SHALL BE REPLACED ONLY BY THOSE SPECIFIED ON THE US&S BILL OF MATERIAL.

NOTES:

I.CIRCUIT DIAGRAM IS FOR HALF OF CAROFILE EACH HALF IS WIRED IDENTICALLY

N24-T

2.C> -CONNECTION TO 34 WAY TERMINAL

BLOCK TBI !OR T82l,TBI IS FOR LEFT HALF: TB2 IS FOR RIGHT HALF

3.STATION SYMBOL "X(Y l"-X IS STATION FOR LEFT HALF OF CARDFILE: !YllS FOR RIGHT HALF

~ CAB OSCILLATOR N451054-1302 JS LOCATED IN A SEPARATE MODULE, ONE CAB OSCILLATOR MAY DRIVE UP TO 20 TRANSMITTER BOARDS.

D 451270-0101 REV 5

Figure 6-23. AF-400 Card File PCB Interconnection Diagram

6-51/6-52

UNION SWITCH & SIGNAL ffi SECTION VII

PARTS LIST

7.1 INTRODUCTION

This section provides a listing of all printed circuit boards for field level maintenance and a complete listing of all component parts (Appendix A) for shop level maintenance.

7.2 FIELD LEVEL COMPONENTS

The following is a list of printed circuit boards that are replaceable at field level. For printed circuit board location refer to Figure 1-3 (sheets 1 and 2).

a. Cab Oscillator PCB b. Coder/Oscillator PCB c. Transimmitter PCB d. Transmitter Power Resistor PCB e. Receiver Input PCB f. Receiver Synchronous Rectifier PCB g. Berthing Timer PCB h. Line Transmitter/Receiver PCB

NOTE

N451054-1302 N451570-830X N451570-190X N451054-930X N451570-300X N451570-2901 N451570-180X N451570-3101

The final suffix number is dependent upon application (frequency, etc.) For those numbers containing an X as the last digit, refer to the tabulation in Appendix A.

In addition to the printed circuit boards, other components that are field replacable, i.e. compling unit with mini bond, are listed in Appendix A.

7.3 SHOP LEVEL COMPONENTS

A complete detailed parts list for shop level maintenance is contained in Appendix A.

7.4 PARTS LIST USE

Mechanical and certain electrical parts are identified by an item number that is keyed to an illustration. Determine part to be replaced and order by part number and description.

Electronic parts are identified by Reference Designations. designations are used on the schematic diagrams to identify part. This same designation is used to identify and locate the applicable printed circuit board. Determine part to be order by part number and description.

These the specific that part on replaced and

7-1/7-2

Parts List

SERVICE MANUAL 6149 APPENDIX A

AUDIO FREQUENCY TRAIN DETECTION AND CAB SIGNALING SYSTEM

AF-400

June, 1983 UNION SWITCH & SIGNAL DIVISION A-6/83-200-2503-1 AMERICAN STANDARD INC. I SWISSVALE. PA 15218


ITEM NUMBER

l

Track Circuit Card File Assembly (N451082-1001) (See Figure A-1.)

QUANT PART t."1JMBE R DESCRIPTION

2 M451083-4901 Bracket, End 2 l M451083-5001 support, Top Guide 3 4

5

1 M451083-5101 Support, Bottom Guide l N451083-4801 Panel, Connector

W/ Resistors 30 J490029 Rivet, 1/8 Alum,

Cab Oscillator Printed Circuit Board (N451054-1302) (See Figure A-2.)

Pop

REFERENCE DESIGNATION QUANT PART NUMBER DESCRIPTION

Q3 l J731186 Transistor, 2N2270 Ql, Q2 2 J731282 Transistor, PN3643-5 -- l J79072 Pad, Transistor

Mounting Rl l J721258 Resistor, llK, l/2W R2 l J720826 Resistor, lBK, l/2W R3 l s.o.T. Resistor, l/2W R4 l J723134 Resistor, 9.lK, l/2W RS, R6 2 J735368 Thermistor, 3000 Ohm R7 1 J721256 Resistor, 3K, l/2W R8, Rll 2 J721250 Resistor, 200 Ohm,

l/2W R9 1 J720883 Resistor, lOK, l/2W RlO 1 J720768 Resistor, 5.6K, l/2W Cl 1 J702956 Capacitor, 22MFD,

35Vdc -

C2 1 -- Capacitor, 4MFD, 200 Vdc

C3, C4 2 J706680 Capacitor, 0.33MFD, 100 Vdc

Ll 1 N451030-0820 Choke, Pot Core Fl l -J710006 Fuse, l/4A, 3AG TPl l J713306-0005 Jack, Test (Yel) TP2 1 J713306-0006 Jack, Test (Red) TP3 1 J713306-0003 Jack, Test (Brn) -- 2 J576794 Clip, Fuse -- 2 J560839 Ejector With Pin

A-2

UNION SWITCH & SIGNAL m 4

.1-------: I ,--- --------i

n:r1 · - - ·· ·-;~· :n '·· i. I "I' . ti:: I

Ii I: i : !:I I i, I I I··! I

d:J ___________ ·-·--- _____________ U!L /~ .11

1· I I•·.

--------. ---------------5

I'

L----_ (IJ __ -__ -_ -- _-_ -__ -_-___ -__ -__ -___ -_-_ -_-==_ - - __ -_-___ - __ - __ -_ -- _==-_ - _-_-_ - ~==--- _==_ - - _-_ - - _----l ___ L/,

.__--------------17-1/16 (INSIDE)--------------.1

i-------------------19-1/16----------------!

l-------'----,---------17-13/16---------------

Figure A-1. Track Circuit Card File Assembly (N451082-1001)

A-3


A-4

( I -I -I

-a -a w N

UN451054-13

fl r..,__ L..r-

+rn, Cl nR2nRI

L J LI LI C4

r L r L r'

01 \__)

c: ::J R3

v --, L

C3

R4

---, _J ---, _J

C:J ,. , ,.. , L.J L.J RS R6

Y. - BK. C2 ·

L _J

A ®_j 'uN451054-13

j COMPONENT SIDE

YUTSRPIIIILKJHFEDCIA REV. 13

Figure A-2. Cab Oscillator Printed Circuit Board Assembly (N451054-1302)

..

UNION SWITCH & SIGNAL ffi Coder/Oscillator Printed Circuit Board (N451570-830X)

(See Figure A-3.)

BASIC COMPONENTS PARTS LIST

QUANTITY I I

REFERENCE GROUP GROUP DESIGNATION -8301 -8302 PART NUMBER DESCRIPTION

I

C2, ClO, Cll 3 3 I J709145-0330 Capacitor, 0.1.MFD, 50 Vdc

C3 1 1 J587173 Capacitor, 1. O.MFD, 35 Vdc

cs 1 1 J706419 Capacitor, 47MFD C6, Clb, C27 3 3 ' J706254 Capacitor, 4 7!-'.i.FD, I

I 20 Vdc

C7 1 1 J709144-0061 Capacitor, lOOPF, 500 Vdc

C8, C9 2 2 J709145-0625 Capacitor, 0.49.MFD, 100 Vdc

Cl2, Cl3 2 - I J709145-0166 Capacitor, 0.01.MFD, 100 Vdc

Cl4 1 - J709145-0330 Capacitor, 0.1.MFD, 50 Vdc

Cl5, C30 2 2 J709145-0614 Capacitor, 1. OMFD, 75 Vdc

Cl 7, C26 2 - J709082 Capacitor, O.OlMFD, 100 Vdc

Cl8, Cl9 2 - J706373 Capacitor, lOMFD,

I 20 Vdc C22 1 1 J709082 Capacitor, O.OlMFD,

100 Vdc C24 1 - J702278 Capacitor, 0 .04 7MFD,

200 Vdc C28, C29 2 2 J706422 Capacitor, 4.7.MFD,

35 Vdc C31 1 1 J709145-0487 Capacitor, 0.022.MFD,

50 Vdc Dl 1 1 J726150-0028 Diode, IN758A, Ref

lOV D2, D8, D9, 4 4 J723555 Diode, IN4003, 200V

Dl4 D3, D4, Dl2, 4 - J726031 Diode, IN914A, SIL

Dl3 SW DS, D6, D7, 4 4 J726031 Diode, IN914A, SIL

DlO SW Fl 1 1 .:,-710074 Fuse, l/4A, 125V I Cl 1 1 J715029-0099 Integrated Circuit,

4027B IC2 1 - J715029-0144 Integrated Circuit,

MC14541B

A-5


Coder/Oscillator Printed Circuit Board (N451570-830X) (Continued) (See Figure A-3.)

BASIC COMPONENTS PARTS LIST (Continued)

QUAN'I'ITY

REFERENCE; GROUP GROUP DBSIGNA'I'ION -8301 -8302 PART NUMBER DESCRIPTION

IC3 1 1 J715029-0204 Integrated Circuit, 4066B

LEDl 1 1 J726150-0062 Diode, Light Emitting Ql, Q2, Q3 5 5 J731398-0079 Transistor, 2N3117

Q8, Ql2 Q4 1 1 I J731186 'I'r ans is tor, 2N2270 QS 1 1 i J731291 Transistor, 2N4037 Q6, Q7 2 2 I J731398-0042 Transistor, DSKl, UJT Q9 1 1 I J731398-0050 Transistor, 2N3964 Qll 1 - i J731398-0079 Transistor, 2N3117 013 1 l

I J715029-0383 Integrated Circuit,

Positive Rect. Rl l l J735405 Resistor SlOK, l/4W R2 1 l I J735519-0227 Resistor, 200K, l/4W R3, R9 2 2 I J735237 Resistor, 2. 2K, l/4W R4, R8 2

. 2 ! J735052 Resistor, 3K, l/4W

RS, RlO, 2 2 J735031 Resistor, lK, l/4W R6, Rl6, Rl9, 14 14 J735031 ( Pr ic- Resistor, Select on

R22, R24, ing Only) Test (SOT) R43-R46, i

R48, RSO, I R52, R54, R59

I R7, R51, R53 " 3 J582510 Resistor, O Ohm .., Rll l l I J735037 Resistor, 33K, l/4W Rl2 l l I J720882 Resistor, lK, l/2W Rl3 l l J735063 Resistor, l .SK, l/4W Rl4 l l J720881 Resistor, 10, l/2W RlS, Rl8, 4 4 J735071 Resistor, 220, l/4W

R20, R23 Rl7, R21 2 2 J735519-0417 Resistor, 215K, l/8W R25, R27, 5 5 J735137 Resistor, lOOK, l/4W

R30, R31 R32

R26 l 1 J721064 Resistor, l.SK, l/2W R28 1 l J735053 Resistor, lOK, l/4W R29 1 l J735036 Resistor, l.lK, l/4W R33, R34, R61 3 - I J735137 Resistor, lOOK, l/4W R35, R38 2 -

I J735031 (Pric- Resistor, Select on

ing Only) Test (SOT)

A-b

UNION SWITCH & SIGNAL ffi Coder/Oscillator Printea C:rcuit Board (N451570-830X) (Continued)

(See Figure A-3.)

BASIC COMPONENTS PARTS LIST (Continued)

' QUANTITY !

I I

REFERENCE GROUP GROUP I D:t;SIG:NA'I'ION -8301 -8302 I PART KUMBER DESCRIPTION I

R36, R47, 4 - i i

J735053 Resistor lOK, l/4W R4 Si, R68 ' l R37 1 - J735068 Resistor, 30K, l/4W

R40 1 - J735079-0034 Resistor, 4.7M, l/4'W l\40 - 1 J582510 Resistor, O Ohm R41, R42 2 - J735300 Resistor, lM, l/4W R5 ~, 1 1 J735406 Resistor, 220K, l/4W R58 1 1 J735404 Resistor, llOK, l/4W R60 1 - J735035 Resistor, 47K, l/4W R62 1 - J735510-0288 Resistor, 750K, l/4W R63 1 1 J735245 Resistor, 62K, l/4W R64, R65 2 2 J735054 Resistor, 20K, l/4W l\66 1 1 J720851 Resistor, lK, lW R67 1 1 J721207 Resistor, 20, lW S\vl 1 1 J725707-0146 Switch, Toggle,

SPDT, PCB 'I'l l 1 N451030-6505 Inductor, Pot Core 'l'.2 1 1 N451597-0618 Inductor, Torroid T4 1 - N451030-7001 Inductor, Pot Core T4 - 1 N451030-7002 Inductor, Pot Core 'I'Jl 1 1 J713306-0006 Tank, Test ( Red) 'I\.J 2 1 1 J713306-0001 Tank, Test (Orange) TJ3 1 1 I J713306-0008 Tank, Test (Black)

TJ4 1 1 J713306-0007 Tank, Test (Blue) TJS 1 1 J713306-0005 Tank, Test (Yellow)

TP1-TP8 8 0 J731432 Turret, Solder Ter-minal

1 1 J576794 Clip, Fuse, PC Type 1 1 M.390S!42 Bushing (T2) 30 30 J731399-0029 Terminal, Solder,

Noninsulated 9 - J79243-'7 Pad, Transistor -

Mounting, Ql-Q3, Q6-Q9, Qll, Ql2

- 8 J792437 Pad, Transistor Mounting, Ql-Q3, Q6-Q9, Ql2

2 2 J560839 Ejector, With Pin 1 1 J776616 PCB, Etched

A-7


Coder/Oscillator Printed Circuit Board (N451570-830X) (Continued) (See Figure A-3.)

FREQUENCY DE'I'ERMH~ING COMPONENTS PARTS LIST

BASIC BOP.~RD TRAIN DETECTION ITEM (Ll) BOARD SUFFIX FREQUENCY DESCRIPTION PART NUMBER

-8301 -8303 l:i90 Hz Inductor N451030-7101 -8301 -8304 2670 Hz Inductor N451030-7102 -8302 -8305 3870 Hz Inductor N451030-7103 -8302 -8306 5190 Hz Inductor N451030-7104

BASIC BOA.RD TRAIN DETECTION ITEM (T3) BOARD SUFFIX FREQUENCY DESCRIPTION PART NUMBER

-8301 -8303 1590 hz Transformer N451030-7105 -8301 -8304 2670 Hz Transformer N451030-7105 -8302 -5305 3870 Hz 'Ir ans former N451030-7016 -8302 -8306 5190 Hz Transformer N451030-7106

BASIC bOARD TRAIN DETEC'l'ION I'I'EM (Cl) BOARD SUFFIX FREQUENCY DESCRIPTION PART NUMBER

-8301 -8303 1590 Hz Capacitor, l .Ot-'lFD J709145-0283 -8301 -8304 267() Hz Capacitor, l.OMFD J709145-0283 -8302 -8305 3870 Hz Capacitor, 1.0.MFD J709145-0283 -8302 -8306 5190 Hz Capacitor, 0 . 8 21"'.iFD J709145-0430

BASIC BOARD TRAIN DETECTION ITEM (C4) BOARD SUFFIX FREQUENCY DESCRIPTION PART NUMBER

-8301 -8303 1590 Hz Capacitor, 0.056.hFD J709145-0073 -8301 -8304 2670 Hz Capacitor, 0. 056.t,".iFD J709145-0073 -8302 -b305 3870 Hz Capacitor, 0. 04 7l'viF'D J709145-0151 -8302 -8306 5190 hz Capacitor, 0 .039.MFD J709145-0150

BASIC BOARD TRAIN DETECTION ITEM (C23) BOARD SUFFIX FREQUENCY DESCRIP'I'ION PART NUMBER

-8301 -8303 1590 Hz Capacitor, 0.056MFD J709145-0073 -8301 -8304 2670 Bz Capacitor, 0.020MFD J709145-0137 -8:,02 -8305 3870 Hz Capacitor, 0.027HFD J709145-0069 -8302 -8306 5190 Hz Capacitor, 0.015MFD J709145-0035

BASIC BOARD TFAIN DETEC'I'ION ITEM ( R39) BOARD SUFFIX FREQUENCY DESCRIP'I'ION PART NUMBER

-8301 -b303 1590 Hz Resistor, 8.2K, l/4W J735058 -8301 -8304 2670 Hz Resistor, lOK, l/4W J735053

A-b

:r.,, I

\.D

FUSE --1 013, '"\ r,-...: ~

Rl5 --c-::J- --~Q7 0 L _,.,09 - E f" "'\ n §,...i: ~ ( ..In" ~' -f l-"\o';-11 H H

\...;f_ ~ :J Rl4 d 014 =i L C5 C L

0·~ ..1. un7n _. sJ O ~22 ~ ~H H 1:;

"' ..J Fl 1,-' RIB :: Q R 6 J 5 L F 2 Q [: :J (}R24 :J ..., [:. :J S2 o DIO I==:] TJ2 rr1 TP5 c -, Fl :_ ~o I

0 • z' -, __. s' .... n; I I ---, C _. , C7 "' I___J Tll/""'\ C :J R21C.'Jc10 u:n 1--, rn\..-& G2? ::;uh),}..., ___J 09 Cl Tl -

1---, Ill +o ;::; LI

___J TJ40C:J0 '\ LI ~

I==:]"' ., " [ ~ /n?; ,--, § E 3 o, c1 [ ~ 12 ;n, °'u '----nJ __, 117 ~ 3 CZ

TIUCk I J R1 C:J C4 .... nu.\ !as

c::::::C 112 ~ ~ . 01 ,,. ~I"~ 1:::1 ::0 ::0 LJ co L :: r--, 0 ./\... c :i

sw, .. ... / "1' ., .J ~, ... ·- '" .------ ~ ;;;; ;;;;;;;; R63

e '.::'. ~ R64

~ ; '-' ::;f I IO O Cl7 C26 012 - DJ 0..0

[ f" '\ 11 11 I I I ~n. II'. =t }

•

, ( ~ 4011 \......J o:2s

O IO

] "- IC 1 6-_ ./ l H l I 1 I t • U Uo t j •

nu;:; n · 0 0 R4o ,cJ O -11')\l')N ... r-, I.I

R67

R4JQC :JO O C :JQR44

R45QC :JO QC, :J QR46

RHQ c JO O C J QR50

R57QC :JO

R49 RO R 5 I R55 R53 R56

:J Q R54

~ UM L J M- <DMMM ~ JPCB-AF400 CODER/ OSCILLATOR .. II&& """'"'"""""' u Cl3 N451570-83 REV

COMPONENT SILK'!,CREEN (M"-'I(., COMPO NEis.iT ~T. = \ 5/~'2.)

Figure A-3. Coder/Oscillator Printed Circuit Board Assembly (N451570-830X)

~ ~ v "' )( .J (ft in IP

I- :t 'Z 1/1 &JI • 20

c£~ _J~~

ut..

-,

_J

c z 0 z ~ ~ :t: RI> c:n G) z }>, r

fB


REFER-ENCE

DE SIG-NATION

TPl

TP2

TP3 TP4

TP6, TP7

TP8, TP9

TPlO

TPll, TP13 Rl R2 R3 R4

R6, R22 R7 Rl5 Rl6, Rl7

RS

R20 R21

Ql, Q3 Q7, Q8 Dl, D5 D3 D4 Cl

C2

C3, C7

A-10

Transmitter Printeo circ~it Board (N451570-19XX) (See Fig~re A-4.)

BASIC C0~20NENTS PARTS LIST

QUANTITY

GROUP GROUP GROUP GROUP GROUP PART -1906 -1905 -1904 -1903 -1902 NUMBER DESCRIPTION

2 2 2 !2 2 J560839 Ejector W/Pin

1 1 1 l1 1 J713306- Jack, Test (Orange) 0001

' 1 1 1 1 1 J713306- Jack, Test (Red) 0006

1 1 l !1 l J713306 Jack, Test (Green) l l l 11 l J713306- Jack, Test (Blue)

l 0007 2 2 2

12 2 J713306- Jack, Test (White)

0002 2 2 2 12 2 J713306- Jack, Test (Yellow)

0005 l l l !1 l J713306- Jack, Test (Brown)

i 0003 I 2 12 2 12 2 J731396 Lug Turret

I

11 I i

l l 11 l J735054 Resistor, 20K, l/4W l Ii l !1 l J735053 Resistor, lOK, l/4W l l 11 l J735052 Resistor, 3K, l/4W I

l l l 11 1 J735519- Resistor, 576 Ohm, I 0386 l/8W

2 2 2 12 2 J735301 Resistor, 51K, l/4W l l l 11 l J735514 Resistor, 6.2K, l/4W l l l 11 l J735138 Resistor, 3.3K, l/4W 2 2 2

12 2 J735050 Resistor, 100 Ohm,

l/4W l l 1 11 l J620850- Potentiometer, lK,

i 0033 3/4W l 1 l l l J721080 Resistor, 2K, 1/2w l l l 1 l J620850- Potentiometer, 200

0076 Ohm, 3/4W 2 2 2 2 2 J731282 Transistor, PN3643-5 2 2 2 '2 ..., J731291 Transistor, 2N4037 L.

2 2 2 2 2 J726031 Diode, 1N914A l l l l l J723914 Diode, 1N753A l l l l l J723555 Diode, 1N4003 1 l 1 ll l J 702139 Capacitor, lOivlFD,

50V 1 1 l l l J706986 Capacitor, lOOMFD,

40V 2 2 2 2 2 J709144- Capacitor, lMFD,

0018 20V

l

UNION SWITCH & SIGNAL ffi Transmitter Printea Circuit Board (N451570-19XX) (Continued)

(See Figure A-4.)

BASIC C0~20KENTS LIST (Continued)

REFER- I QUANTITY ENCE

GROUP' GROUP' GEOUP DE SIG- GROUP GROUP PART NATIOK -1906 -1905 -1904i -1903 -1902 NUMBER DESCRIPTION

' I I c~ ! -- -- -- -- -- Capacitor, (Fur-I nished with Tl)

53 1 1 1 1 1 J725707- Switch, Toggle 0146 SPDT

Sl 1 1 1 l l J725707- Switch, Rotary I 0057

SPl, SP212 2 2 .2 2 J790876 Varistor, V39ZA6 Q7, Qb 2 2 2 .2 2 J792072 Pad, Mounting Fl, F2 14 4 4 4 4 J576794 Clip, Fuse Fl .1 l l 11 ,1 J710006 Fuse, 0.25A, 250V F2 l l l l Ii J710090 Fuse, 3A, 250V Tl l l l 1 N451030- Inductor, Pot

f 1

4924 Core T3 1 l 1 l N451030- Inductor, Pot

. 4923 Core T4 11 l l I 1 1 N451030- Inductor, Pot

I I I 5411 I I Core 11

l

R23 l l I 1 !1 J735519- Resistor, 30 Ohm, I ; 0389 l/4W I I

12 i

Rl8, Jil9 2 2 2 j2 J735139 Resistor, l.8K, ! ! l/4W

J 1

i

Q2 l l l 11 J731398- Transistor, 2N5962 0040

l 1 1 11 '1 N451570- PCB, Basic I I 1901

RS 1 1 l l -- J735054 Resistor, 20K, l/4W R9, RlO l l 1 1 -- J735053 Resistor, lOK, l/4W Rll l 1 1 l -- See Tab Resistor Rl2 l l 1 I l I -- See Tab Potentiometer I

1 1-- J735301 Resistor, 5 .lK, Rl3 l l l , __ l/4W

Rl4 1 l l l J735514 Resistor 6 .2K, l/4W Q4, Q6 2 2 2 2 -- J731282 'I'ransistor, PN3643-5 C4 1 1 1 1 -- J709144- Capacitor, lMFD,

0018 20V S2 1 1 l 1 -- J725707- Switch, Rotary

0057 T2 l 1 1 1 -- See Tab Inductor, Pot

Core

A-11


Transmitter Printed Circuit Board (N451570-19XX) (Continued) (See Figure A-4.)

BASIC COMPONEKTS PAR'I'S LIST (Continued)

QUANTI'IY REFERENCE

DESIG- GROUP GROUP GROUP GROUP GROUP PART NATION -1906 -1905 -1904 -1903 -190~ NUMBER DESCRIPTION

D2 1 l l 1 1-- J726031 Diode, 1N914A TPS 1 l 1 1 -- J713306- Jack, Test (Blue)

0007 TP12 1 1 l 1 -- J731396 Turret Lug R24 l l 1 1 -- See Tab Resistor QS l l 1 1 -- J731398- Transistor, 2N5962

0040

FREQUENCY DETERMINING COMPONENTS PARTS LIST

BOARD I'I'EM (T2 W/C6) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-lS.02 990 --- ---1903 1590 Transformer with N451030-4925

Capacitor -1904 2670 Transformer with N451030-4926



Capacitor

BOARD ITEM (Rll) SUFFIX FkEQ (Hz) DESCRIPTION PART NUMBER

-1902 990 -- ---1903 1590 l.05K J735519-0387 -1904 2670 5.23K J735519-0130 -1905 3870 10.5K J735096 -1906 - 5190 llK J735100

BOARD ITEM (Rl2) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-1902 990 -- ---1903 1590 2K J620850-0068 -lS.04 2670 lOK J620850-0058 -1905 3870 20K J620850-0063 -1906 5190 2CK J620850-0063

A-12


EB ............ :;: ................ e, ~ , ~ ~ - ~ ~ , ~ • .a.w c:, - en ...... h.>

:;:nnnnnnnnnn:;: c "04 ·

• LJ W LJ LJ W LJ LJ L.J L.J W"' RB / c ::J

n Cl

LJ

J REV. 3

VUiSRPNMLKJHFEOCBA

Figure A-4. Transmitter Printed Circuit Board Assembly· (N451570-19XX)

A-13


Transmitter Printed Circuit Board (N451570-19:XX) (Continued) (See Figure A-4.)

FREQUENCY DE'I'ER.tvlINING COZ.lPONENTS PARTS LIST (Continued)

BOARD ITEM (R24) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-1902 990 -- ---1903 1590 33 Ohms J735519-0057 -1904 2670 24 Ohms

I

J735519-0388 -1905 3870 27 Ohms J735519-0324 -1~06 5190 27 Ohms J735519-0324

'l'ransmitter Power Transistor Printed Circuit Board (N451054-93:XX) (See Figure A-5.)


REFERENCE DB~IGJ.'..ATION QUAN'l' PART NU.HEER DESCRIPTION

Ql, Q2 2 J731263 Transistor, 2N3055 (-9301)

Ql, \.!2 2 - J731398-0074 Transistor, 2N6578 (-9302)

-- 4 J050999 Screw, 4-40 x 1/2

I Bind.

-- 4 J047729 Washer, 4 Int. T. Lm. -- - 4 J480006 Nut, 4-40 Hex. s -- 2 J792399 Sink, Heat -- 4 J525038 Screw, #10-32 x 7/16

Rd. s. -- 4 J475077 Washer, 10 Plate -- 4 J047733 Washer, 10 Lock -- 4 J048172 Nut, 10-32 Hex -- 2 J560839 Ejector With Pin

Receiver Input Printed Circuit Board (N451570-30XX) (See Figure A-6.)



TL1-TL9 9 J731432 Lug, Turret TPl 1 I J713306-0006 Jack, Test (Red) TP2, 3 2 J713306 Jack, 'I'es t (Green) TP4 1 I J713306-0002 Jack, Test (White) TP6 1 I J713306-0003 Jack, Test (Brown)

' I

A-14

UNION SVIIITCH & SIGNAL m UN451054-93

Ql

Q2

V I I I I I

--, L

YUTSRPNMLKJHF[DCBA

A 6,_j r;.451054:93XX

J COMPONENT SIDE

REV. 7

Figure A-5. Transmitter Power Transistor Printed Circuit Board Assembly (N451054-93XX)

A-15

m UNION ~ITCH & SIGNAL

Receiver Input Printed Circuit Board (N451570-30XX) (Continued) (See Figure A-6.)

BASIC CO~.LPONENTS PARTS LIST (Continued)


TPS 1 J713306-0005 Jack, Test (Yellow) 1-1.5 1 J735052 Resistor, 3K, l/4W R6 1 J582510 Resistor, 0 Ohm Rl7 1 0735034 Resistor, 4.7K, l/4W R8 -- -- Resistor, S.O.T., l/4W R5i -- -- Resistor, S.O.T. I l/4W RlO, Rl8 2 J735519 Resistor, 22K, l/2W

(4 Term) Rl2 1 J731405-0013 Thermistor 1000 Ohm Rl3 1 J735049 Resistor, 620, l/4W Rl5 1 J735139 Resistor, l.8K, l/4W Rl6 1 J735068 Resistor, 30K, l/4W Rl9 1 J735031 Resistor, lK, l/4W R20 1 J735301 Resistor, 5.lK, l/4W R21 1 J735057 Resistor, 10 Ohm, l/4W Dl 1 J726082 Diode, 1N959B Zener,

8.2V D2, 3, 4 3 J726031 Diode, 1N914A Q3 1 J731398-0027 Transistor, 2N5087 Q2, Q4 2 J731398-0026 Transistor, 2N5210 Cb l J706762 Capacitor, 0.47MFD,

lOOV, (4 term) C7 1 J706986 Capacitor, lOOMFD, 40V Fl l J071190 Fuse, 1/2 Amp, 250V

2 J576794 Clip, Fuse, Fl -- 2 J560839 Ejector W/Pin -- -- A043183 W-#22 Bare Tinned

Copper

FREQUENCY DETERtHKING COHPONENTS PARTS LIST

BOARD I'l'EM ( Rl) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 47 J732548 -3003 2670 91 J735519-0424 -3004 3670 0 J582510 -3005 5190 0 J582510

A-16

-

UNION SWITCH & SIGNAL ffi Receiver Input Printea Cir~uit Board (N451570-30XX) (Continued)

(See Figure A-6.)

FREQUENCY DETERMINING COMPONENTS PARTS LIST (Continued)

BOARD I ITEM. ( R2) SUFFIX FREQ (Hz) I DESCRIP'I'ION PART NUMBER

I -3002 1590 I 0 J582510 -3003 2670 0 J582510 -3004 3870 20 J735519-0411 -3005 5190 18 J735519-0423

E:.OARD I ITEM (R3)

I SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 0 J582510 -3003 2670 0 J582510 -3004 3870 18 J735519-0423 -3005 5190 10 J735057

BOAR[; 1 ITEM ( R4) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 240 , J735519-0060 -3003 2670 110 J735515 -3004 3870 100 J735050 -3005 5190 I 0 J582510

E:.OARD I ITEM ( Rll) · SUFFIX FREQ (Hz) ' DESCRIPTION PART NUMBER

l i

-3002 1590 • 470 J735141 l

-3003 2b70 j 620 J735049 -3004 3870 l 620 J735049 l

I

620 J735049 -3005 5190 I I

BOARD

I ITE!-'1 (Ll \v/Cl)

SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 Pot core Inductor N451030-5141 -3003 2670 ·pot Core Inductor N451030-5142 -3004 3870 Pot Core Inductor N451030-5143 -3005 5190 I Pot Core Inductor N451030-5144

BOARD I I'IEt-: (L2 v~/c3) SUFFIX FREQ (Bz) I DESCRIPTION PART NUMBER

I

-3002 1590 Pot Core Inductor N451030-5512 -3003 2670 Pot Core Inductor N451030-5513 -3004 3870 Pot Core Inductor N451030-5514 -3005 5190 i Pot Core Inductor N451030-5515

I

I

A-17


Receiver Input Printed Circ~it Board {N451570-30XX) (Continued) (See Figure A-6.)

FREQUENCY DETEfil'iINING CO!-'iPONENTS PARTS LI ST (Continued)

BOARI.i ITEM (Tl) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 Transformer N451030-5413 -3003 2670 Transformer N451030-5414 -3004 3870 Transformer N451030-5415 -3005 5190 Transformer N451030-5416

BOARD ITEM (T2 W/C2) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 l!:>90 I Pot Core Inductor N451030-6201 -3003 2670 Pot Core Inductor N451030-6202 -3004 3870 Pot Core Inductor N451030-6203 -3005 5190 Pot Core Inductor N451030-6204

BOARD ITEM (T3 W/C4) (

SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 Pot Core Inductor N451030-5508 -3003 2670 Pot Core Inductor N451030-5509 -3004 3870 Pot Core Inductor N451030-5510 -3005 5190 Pot Core Inductor N451030-5511

BOARD ITE:h ( '!'4 v,i/ cs) SUFFIX FREQ (Hz) DESCRIPTION PART NUMBER

-3002 1590 Pot core Inductor N451030-5504 -3003 2670 Pot Core Inductor N451030-5505 -3004 3870 Pot Core Inductor N451030-5506 -3005 5190 Pot Core Inductor N451030-5507

Receiver Syr,chronous Rectifier Printed circuit Board (N451570-2901) (See Figure A-7.)

REFERENCE DESIGJ:-JA'IIO:t:-i QUANT - PART NUMBER DESCRIPTION

Rl l J735050 Resistor, 100 Ohm, l/4W ~I R22, R24 3 J735301 Resistor, 5.lK, l/4W R3 l J735139 Resistor, l.8K, l/4W R4, RS 2 J735405 Resistor, SlOK, l/4W R6, R29 2 J735048 Resistor, 2K, l/4W R7 l J735052 Resistor, 3K, l/4W RB l J73519-0073 Resistor, 300 Ohm, l/4W R9 l J735388 Resistor, 13K, l/4W

A-18

UNION SWITCH & SIGNAL m

~ r REV. 2

'I

VUTSRPNMLKJHFEOCBA

Figure A-6. Receiver Input Printed Circuit Board Assembly (N451570-30XX)

A-19


Receiver Synchronous Rectifier Printed Circuit Board (N451570-2901) {Continued) (See Figure A-7.)

REFERENCE DBSIGNA'lION

RlO, R.23 Rll Rl2 Rl3 Rl4, R21 RlS, Rl6,

Rl7 Rl8 Rl9 R20 R23, R25 R27 R28 R31 Cl C2

C3

C4

cs

C6, C7 cs C9, ClO Cll Cl2, Cl3 Cl4 Dl, D4, D8 D21 D3 DS, D6, D9,

DlO D7 Dll LED 1 Ql, G5 Q2, Q6 Q3, Q4,

Q9, GlO Q7 Q8 Ql, Q2, QS,

Q6, QB I Cl

A-20

QUANT

2 1 1 1 2 3

l 1 l 2 l l l l l

--l

--2 1 2 l 2 1 3

l 4

l -- 1

1 2 2 4

1 l

5 l

PAR'I' NUMBER

J735054 J735366 J735063 J735245 J735053 J735031

.1735247 J735514 J735300 J620850-0062 J735057 J720820 J735037 J706988 J709052

J709145-0069

J706501 J706678 J706120 J706986 J706436 J706940 J723555 J726150-0141 J726150-0093 J726031

J726150-0071 J726020 J726150-0062 J731398-0006 J731291 J731398-0040

J731398-0027 J731304 J792072

J715029-0310

DESCRIPTION

Resistor, 20K, l/4W Resistor, 24K, l/4W Resistor, l.SK, l/4W Resistor, 62K, l/4W Resistor, lOK, l/4W Resistor, lK, l/4W

Resistor, 560 Ohm, l/4W Resistor, 6.2K, l/4W Resistor, 1 Meg, l/4W Potentiometer, SOK, 3/4W Resistor, 10 Ohm, l/4W Resistor, l.2K, l/2W Resistor, 33K, l/4W Capacitor, 210MFD, 40V Capacitor, 47MFD,

SOV, 4 Lead Capacitor (Fu~nished

with T2) " Capacitor, 0.027MFD,

200V Capacitor, (Furnished

with T2) Capacitor, 6.8MFD, 35V Capacitor, 27MFD, 20V Capacitor, lMFD, lOOV Capacitor, lOONFD, 40V Capacitor, O.lMFD, SOV Capacitor, lOOPF Diode, 1N4003 Diode, 1N5289 Diode, LVA450, Zener Diode, 1N914A

Diode, N748A Zener Diode, 1N963B Diode, Light Emitting Transistor, 2N3053 Transistor, 2N4037 Transistor, 2N5962-18

Transistor, 2N5087 Transistor, 2N2102 Transistor Mounting Pad

Integrated Circuit, MC14538

:i,, I "-' I-·

EB

ls

r-- -1 EB

! --1 Fl '-]CI I or. 04 ., '1• Of, I l 1 O R? 7

I ' o I J O I J O

_R15 _n_ + ((•~ fr.\\:'_ 0 :_ o [ ]-:RI I 03 _C5 L _}----

: ~:R,;i J-·"J \i,._•) I \ ),._·) /,7::,'f \C:S l •-{ J-"R 14+ C7""- _/ ""- _/ o:: ~

J ,- 0 -... o O 04 T 2 R8

]

" 1 • L 0 -{I 0 [

i J-oo-[ }oL

-, •-{[ (•D6 CB TL30 o-{I J-• L~J r'1 C3l ~12 ci" 0 + J \1? +·-{ ]-~\_ L Lr' -.1 '-- ./ R2 ~- CI 3 o o -

]- / - -, • c,,. ,._ - ) f • \02 r l r~ R:i

A= a:,:r'-P. C6 I ~ ------ l 2 0 • [

TP2 a O r', 09• • J 1L_0 ./•01L J ] / ~u ~ R26_•{ 1 .. '- • J ~ f ~~ •-{_. J}-•D2

o T 0 L_J R31•- o@== o Hr -TP r ~ 0 ,_ [TJ r_1 4 0 - - • 0 - ' ; 0 ° L. n °

.-1 08 0:: 0 ' 0 0 0 - 0 0 (,-___ _/ 1 0 () ]/ 0 -y O r J u=€lo~ "' I \ 0 ). J DI() . lL?

- TP-1 t-r7 ."- 0 0 • _ _,.,, O, 0 '11 01 ° oa--· llll . y ~r ~ I O O \ ~'! : : ('J ,,;?' ·(9 ! I n TP3 ~\__ ~ •·• 2(! "(;'; ".,r.

RI O O 2:o o ]

/ 0 0 0 f"') O o

TP5 o-( J-o ~-- --, ~ __J ]/ (q= _,

RIB o-{ J-o

.,.r N 0:

0

R25 r',

-, r -, oCJ1o

Ff'r'i

c c

R23

Jy ]·

L

N451570-2901 REV.

0 0

--"--- 0

IC I 0

Ju •·{ J-• R22 · L

'r' 1,J

i;'}L~L_ 0

BK O c::,====a

Tl

' I r

L .-~I :, ==== 00 ===

·L I l nfl7 7 I

JnfM I 'c0c___f --

}oQ3, Jo::r=-===TJm H} ~~~-___ : ____ -_jf

1c2

I 0 ll I

RL y I

_J

[ [- ______ :J, c----- Jv

r:--=~--- I , I I • [ - ~~~-=:-~: - J z

L ::--~= I n

L ___ . __ -· _ I ~ L ___ I~ [ _______ ]~

[ ____ · r:= __ -n> ,-1

"----EB __ j

Figure A-7.

COMPONENT SIDE MAX. COWONENT HE: I GHT • I 3 116

WARNING:


Receiver Synchronous Rectifier Printed Circuit Board Assembly (N451570-2901)

c z 0 z ~ ~ :I: II!' (I)

G) z )> r

EE


Receiver Synchronous Rectifier Printed Circuit Board (N451570-2901) (Continued) (See Figure A-7.)

REFERENCE Dl:.5IGNA'IICN QUANT PART NUMBER DESCRIPTION

IC2 1 J715029-0089 Integrated Circuit, MC14001

IC3 1 J715029-0174 Integrated Circuit, GE HllBl

Tl 1 K451039-4701 Transformer T2 l l\451030-4713 Inductor, Pot Core RLY 1 1 J726153-0086 Relay, HGJ2MT51231NOO Fl 1 J071190 Fuse, 1/2 Amp -- 2 J576794 Clip, Fuse TPl 1 J713306-0006 Jack, Test (Red) TP2 l J713306-0001 Jack, Test (Orange) TP3 l J713306 Jack, Test (Green) TP4 1 J713306-0002 Jack, Test (White) TPS 1 J713306-0005 Jack, Test (Yellow) TP6 l J713306-0003 Jack, Test (Brown) TP7 l J713306-0007 Jack, Test (Blue) TLl, TL2, 4 J731432 Turret, Solder Term.

TL3, 'I'L4 -- ~ J792254 Sink, Heat, Q5, Q6 -- l J725840-0004 Socket, 16 Pin -- l J725840-0005 Socket, 14 Pin

2 J560839 Ejector, W/Pins

Printea circuit Boaro File Assembly (N451088-3401) (See Figure A-8.)

ITEM NU:hBER QUANT PART NU!v~BEF- DESCRIPTION

1 1 R451593-0902 Box, Weldment 2 4 J706533 Connector 3 8 J712067 Guide, Card 4 2 M451593-1001 Bar, Support 5 4 J507018 Screw, 6-32 x 1/4 6 8 J052523 Screw, 6-32 x 1/2 7 8 J-047996 Washer. #6 Flat 8 8 J047662 Washer. #6 Lock 9 8 J048148 Nut, 6-32 Hex

BDH RRD

UNION SWITCH & SIGNAL EE c~e i=)

(A) e/2,-z.. 1-101...1:~ DRAWING D451088 SH. 34, REV. O

I n 4 I

~--------_J ,, 5

4

n ri, 3

r- - " ~: ·~: : -t ;

'8t " ti

a ' ' ' ' ---"" ,._ __ ..,

I--------1

3~~==~~~;!:::=~~

I I

I ; ' ' ..._,

It

fJ ~N ~

\9 UI ~·

d)f~ r-

Ii' :1 '-

'!.11~ r-

- ,----- .... --

3 $

..----------B.!. (fZ,;,:.) 8

51i:C ,-, O"-' A.- A.

- - I

CO~NECTO~ M0Ui.JiU,.lC:, H01-E

6 7 8 9

Figure A-8. Printed Circuit Board File Assembly (N451088-3401)

A-23


Berthing Timer Printed Circuit Board (N451570-18XX) (See Figure A-9.)

REFERENCI!. DESIGNA'IION

Rl, R2, k6, R7

Rl, R6 R2, R7 R3, k8

R4, R9 RS, RlO

Dl, D2 Ql, Q2 MOVl, MOV2 ICl, IC2

Cl, C6

C3, C8

C4, C9

CS, ClO

C2, C7 Ql, Q2 Fl, F2 Fl, F2

QUANTITY

GROUP -1802

2

2 2 2

2 2

2 2 2 2

2

2

2

2

2 2 4

GROUP -1801

2

4

2

2 2

2 2 2 2

2

2

2

2

2 2 2 4 2

PART NUMBER

J560839

J735519-0177

J720882 J735519-0264 J721065

J721212 J720863

2W J723918

IJ731381 J735525 J715029-0218

J706419

J709144-0072

J709082

J701926

S.O.T. J792072 J710007 J576794 J560839

DESCRIPTION

Ejector W/Pin

Resistor, 681K, 1/BW

Resistor, lK, l/2W Resistor, 487K, l/8W Resistor, 470 Ohm,

l/2W Resistor, 24K, l/2W Resistor, 300 Ohm,

Diode, 1N3017B Transistor,, MM4001 Varistor, V95LA7A Integrated Circuit,

MC1555 Capacitor, 47MFD,

35V Capacitor, l.S~~D,

50V Capacitor, . OlMFD,

lOOV Capacitor, .OlMFD,

400V Capacitor Mounting Pad Fuse, 1 Amp, 250V Clip, Fuse Ejector, W/Pin

Line Transmitter/Receiver Printed Circuit Board (N451570-3101) (S~e Figure A-10.)

REFERENCE -

DESIGNATION QUANT PAR'!' NUMBER DESCRIPTION

TPl l J713306-0006 Jack, Test ( Red) TP2 1 J713306-0003 Jack, Test (Brown) TP3 1 J713306 Jack, Test (Green) TP4 1 ,J713306-0005 Jack, Test (Yellow) 'I'PS 1 J713306-0001 Jack, Test (Orange) TP6 1 J713306-0002 Jack, Test (White) Cl, C3 2 J709035 Capacitor, 0.001 .MFD,

900V C2, C4 2 J706986 Capacitor, 100 MFD, 40V

A-24

N451570-

[ ]3+ C6

o"~ []

CB

_n n<Cn n'"'u LI'"' C9

RlO LJ LJ

IC2

RS

n ClO

,, '-'

LJ 02

REV.

n n r , r, 02 01

t::::S t:::i

C2 o~

n LJ

[] R2n

u

Cl

Rln n LI C4LJ

. '"""" ,

-IC1 ,, nR3 \.__,6


n c µ

LI a1

n r1

n io JI "u ... ·O JI u" ~~ ~~

L.J L.J

A EB_j r

V I I

--, I I

L J REV. 3

VUTSRPNMLKJ Hf fDCBA

Figure A-9. Berthing Timer Printed Circuit Board Assembly (N451570-18XX)

A-25


Line Transmitter/Receiver Printed Circuit Board (N451570-3101) (See Figure A-10.)

REFERENCE DE;SIGNATION

Rl R2, Rl4, Rl 7 R3, Rl6, Rl8 R4, Rl3 RS, Rl2 R6 R7 R8, R9 F..10, R23 R7 Rl5 Rl9 R2CJ R22 R21 Ql, Q2, Q7 Q3 Q4, QS, Q6 Ql, Q2, Q7

Q3, Q4, QS, Q6

Dl LEDl, LED2

I Cl, IC2 Fl, F2 Fl, F2 SPl, SP2

R24, R25 R2G, R27 Rll

ITEM

QUANT

l 3 3 2 2 l l 2 2 l 1 1 1 l 1 3 1 3 3

4

1 2

2 2 4 2

2 2 2

PART NUMBER

J735053 J735048 J735031 J735034 J735519-0073 J735035 J721121 J723431 J720881 s.o.T. J735052 J735236 J735066 J735071 J720851 J731282 J731186 J731283 J792437

J792072

J723555 J726150-0062

J731457 J071190 J576794 J735535

J735148 J721189 J731396

DESCRIPTION

Resistor, lOK, l/4W Resistor, 2K, l/4W Resistor, lK, l/4W Resistor, 4.7K, l/4W Resistor, 300 Ohm, l/4W Resistor, 47K, l/4W Resistor, 680 Ohm, lW Resistor, 62 Ohm, lW Resistor, 10 Ohm, l/2W Resistor Resistor, 3K, l/4W Resistor, 390 Ohm, l/4W Resistor, 3.9K, l/4W Resistor, 220 Ohm, l/4W Resistor, lK, lW Transistor, 2N3643 Transistor, 2N2270 Transistor, 2N3644 Pad, Transistor:

Mounting Pad, Transistor

Mounting Diode, 1N4003 Diode, Light Emitting,

5082-4415 Coupler, Optical, HllFl Fuse, O.SA, 250V Fuse, Clip Varistor, 19 Vdc

V24ZA4 Resistor, 15 Ohm, l/2W Resistor, 47 Ohm, l/2W Lug, Turret

Tuning Panel Assembly (N451052-3301) (See Figure A-11.)

NU!v.J3ER QUANT PART NUMBER DESCRIPTION

1 1 1'1451053-6102 Hinge 2 1 h451053-6101 Panel 3 3 J507266 Screw,10-32 x 3/8 Pnh

Stl 4 3 J475077 Washer, 10 Stl Pl 5 3 J047733 Washer, 10 Stl Lk 6 3 J048172 Nut, 10-32 Hex Stl

A-26


::::0 :z: rr; ..r:,. <V1

0

EB nnnnnnnnEB LJ ; 1 u u, 1 u2-JuLrn2

~- ~ 0000

LEDi TP2 TP5 TP6 TP4 TP:3 TPI

Rl5 o-{ }-o

o-{ }-o RI -4

~ ·{ o-{ }-e

•-{ ]-oRl7 ?\ 0 0 0

•-{ J-o RIB <.,J\_•_.) o-{ J-o RI 3

·@-{ J-0Rtl /e~

(•\ 0 0 0 o-{

o-{

~ : e J }-oR6 ::o o

u, N \_ ./~

' --, - • 0

(") 0

N o o

o-{ }-• ::0

N

[ J (") l,J

_r"'._ •

(.ll

-u N

J-•R4 y 0

c~~ C2 '

(")

Ii

vu>SRPNMlKJHFEOCS•

0 y

0

0

r1-, ::0 N <.,J

Figure A-10. Line Transmitter/Receiver Printed Circuit Board hssembly (N451570-3101)

~-27


ITEM NUhBER

7

8

CJ ..,

10 ll 12

IT Eh NU.MEER

l

2

3

4

5

6

7

8

s, lO ll

-

12 13

14 15

16 17

A-28

Tuning Panel Asserr~ly (N451052-3301) (Continued) (See Figure A-11.)

QUANT Ph.RT NU!>'IBER DESCRIPTION

l N451522-8901 PCB, AF Tuning (See Figure A-12 for Breakdown)

6 J507262 Screw, 6-32 x 3/8 Pnh Stl

1 !vi4 5110 8-5 2 0 2 Plate, Name

2 J490037-0001 Rivet, 1/8 Dia. Pop 1 J792797 Fastener, 1/4 Turn 1 J712065 Retainer, #5 Stud

Tuning Panel Printe6 Circuit Board (N451522-8901) (See Figure'A-12.)


Cl, CB j 2 J709145-0406 Capacitor, 0.003:MFD, 270V

C2, C7 I 2 J709145-0407 Capacitor, I I 0.004MFD, 270V

C3, C6 2 J709145-0404 Capacitor, O.OOlMFD, 270V

C4, cs 2 J709145-0405 Capacitor, 0.002MFD, 270V

C9, Cl6 2 J709145-0410 Capacitor, 0.03MFD, 270V

Cl2 ,Cl3 2 J709145-0409 l Capacitor, 0.02MFD, 270V

Cll, Cl4 I

2 J709145-0408 Capacitor, O.OlMFD, 270V

ClO, Cl5 2 J709145-0411 Capacitor, 0.04MFD, 270V

--I -- r J714063 Lug, Turret 0

-- 6 J792798 Stand Off, 6-32 Thds

-- 1 J725710-0020 Strip, Term 13 Way -- 2 J525017 Screw, 6-32 x 3/4

Rdh Stl -- 2 J047662 Washer, 6 Stl Lk -- 2 J047996 washer, 6 Stl

Plate -- 4 J725707-0079 Switch, Rotary -- 2 J048148 Nut, #6-32 Hex Stl

~. I I

N \.0

I 178

----------------------=--182.._ (RE~) ,~ 20-- - ----- ·------------------

I'' -~--- ----------······--.--.---- ------- --- -- . -~ -- -------- ----- : tt-; 1 ---

! • """ (f) + $ '=•m@ ! ! : • <t} \ 11 I t !\-It ~1'"' j

14 Ta, U , r

: o" o~ [Hf· • \,o er .. Q·O"· , : I I ~ : [} OciOODC4 U~G·o~c,,o~·i . I 1' I -@ I·- 11

. - ~ I • • 2 j

: •® """• $. . (!, coa,,., ~ ( ~ <t} 1 '+__.,.,_' __.._!

-......_ '--

-$

I

lt DRAWING pl_i5J:052 SH. 33? REV. 2

Figure A-11. Tuning Panel Assembly (N451052-3301)

...

c z 0 2

¥E =i 0 :c ll'> (/)

Cl 2 )> r

EB

:i:,. I

t,J 0

~,

~L

"'" (} (~ 0 0 COARSE I

\ I

n I 1

2

- - 3 TBI

4

0 0 n n n n n n n n C5 C6 C7 cs Cl3 C14 CIS Cl6

n n r1 n u u u LJ n n n n LJ u LJ LJ Cl C2 CJ C4 C9 CID C11 C12

5

6 EB. UNION SWITCH l SIGNAL DIVISION

AM(lt1~lH 1,UNOHIO UH. \WI\\Y&lf ,.l l',7•11 MAti• lk IJ'.•

u LJ u LJ LJ LJ LJ LJ 0 0

I

2

3 , - TB2

() '"" 0 0

() '""'' UN45152,'-8901 REV.

4

5

6

I_J _J~

Figure A-12. Tuning Panel Printed Circuit Board Assembly (N451522-8901)

fE c z 5 z ~ :j 0 :c RO (I)

i5 z )I, r

I""-;:. Iv J..;..J ....

Nl.JhBER

1 2 3

4 5

UbiIT SUFFIX

-O~Gl -0902 -0903 -0904

ITE!-'J NUI-...Bl:;k

1 2 3

4 5

UNIT SUFFIX

-1001 -1002 -1003 -1004 -1005


Coupling Unit Ki~h ~inibond (N451003-09XX) (See Figure A-13.)

BASIC CSEPOKENTS PARTS LIST

QUA.bl'I' Pl-.RT NUMBER DESCRIP'I'ION

1 N452.003-0701 Mini bond 1 See Aux Tab Unit, Coupling 5 J05C050 Screw, 3/8-16 x 5/8

Hex Hd 5 J047779 Washer, 3/8 Stl Lk 5 J04'7502 Washer, 3/8 Stl Plate

FREQUENCY DETEFJ·~:i:KING COMPONENTS PARTS LIST

ITEM FREQ (Hz) DESCRIPTION

990, 1590, 267C Coupling Unit 990, 2670, 387G Coupling Unit 990, 3b70, 5190 Coupling Unit 990, 5190, 1590 Coupling Unit

Coupling Unit ~ith Minibond (N451003-10XX) (See Figure A-14.)


PART NUMBER

N451052-3201 N451052-3202 N451052-3203 N451052'-3204

QUA.NT PJ..RT NUMBER DESCRIPTION

1 N451003-0701 Mini bond 1 See Aux Tab Unit, Coupling 5 J050050 Screw, 3/8-16 x 5/8

Hex Hd 5 J047779 Washer, 3/8 Stl Lk 5 J047502 Washer, 318 Stl Plate

FREQUENCY DETER!w.INING COMPONENTS PARTS LIST

ITEM FREQ (Hz) DESCRIPTION PART NUMBER

990, 1590, 2670 Coupling Unit N451052-3401 990, 2670, 3870 Coupling Unit N451052-3402 990, 3870, 519C Coupling Unit N451052-3403 990 I 5190, 1590 Coupling Unit N451052-3404 990, 1590, 2670 Coupling Unit N451052-3405

A-31


WAV!>II)E CABl..E

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DRAWING F451033 SH. 9, REV. 3 ! ! i I

m I I I f---------15 17.---------I ..-------nk,------------;

Figure A-13. Coupling Unit With Minibond Assembly (N451003-09XX)

A-32

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WAV51.:>E CA"BLE ACCE.S!:>

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DRAWING F451033 SH. 10, REV. l

UNION SWITCH & SIGNAL ffi I/MF.

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Figure A-14. Coupling Unit With Minibond Assembly (N451003-10XX)

A-33/A-34

audio frequency train detection and cab signaling system …€¦ · train detection and cab...

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