solid state grs/alstom style biased code responsive relay · responsive relay. this relay provides...

SM 9025 1000 Technology Drive, Pittsburgh, PA 15219

645 Russell Street, Batesburg, SC 29006

Solid State GRS/Alstom Style

Biased Code Responsive Relay

Hitachi Rail STS USA Part Numbers Functional Equivalent for

N320030-01 A62-598 N320030-02 A62-157 N320030-03 A62-156 N320030-04 A62-595 N320030-08 A62-622 N320030-09 -

Installation

Operation

Solid State GRS/Alstom Style Biased Code Responsive Relay

Copyright 2019 SM 9025 Rev. 5, March 2019


Copyright 2019 SM 9025 Rev. 45, March 2019 i

Proprietary Notice This document and its contents are the property of Hitachi Rail STS USA, Inc. (formerly known as Union Switch & Signal Inc., and hereinafter referred to as "STS USA"). This document is furnished to you on the following conditions: 1.) That no proprietary or intellectual property right or interest of STS USA is given or waived in supplying this document and its contents to you; and, 2.) That this document and its contents are not to be used or treated in any manner inconsistent with the rights of STS USA, or to its detriment, and are not to be copied, reproduced, disclosed or transferred to others, or improperly disposed of without the prior written consent of STS USA.

Important Notice STS USA constantly strives to improve our products and keep our customers apprised of changes in technology. Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability. The data contained herein purports solely to describe the product, and does not create any warranties.

Within the scope of the attached manual, it is impossible to take into account every eventuality that may arise with technical equipment in service. Please consult an STS USA local sales representative in the event of any irregularities with our product.

STS USA expressly disclaims liability resulting from any improper handling or use of our equipment, even if these instructions contain no specific indication in this respect. We strongly recommend that only approved STS USA spare parts are used as replacements.


Copyright 2019 SM 9025 Rev. 45, March 2019 ii

Revision History Rev. Date Nature of Revision

0 January 2003 Original Issue

1 June 2003 Incorporated ECO 139838-4; clarify application of the solid state relay.

2 October 2005 Incorporated ECO EE-1832; added part number N320030-08.

3 February 2009 Incorporate ECO Cs-0075, EE-1788, and EE-1785. Location of front label revised, revised, and Figure 2-1 revised.

4 October 2013 Added N320030-09 part number to cover, added Figure 1-2, Figure 1-4, and Section 1.5. Revised Figure 2-1, Section 1.3, Section 2.2, Section 2.6, Table 1-2, Section 2.2, and Section 4.2. Changed Figure 4-1 title.

5 March 2019 Hitachi Rail STS Branding


Copyright 2019 SM 9025 Rev. 45, March 2019 iii

Table of Contents

1. INTRODUCTION ............................................................................................................................... 1-1

1.1. Glossary .................................................................................................................................... 1-1 1.2. Description ................................................................................................................................ 1-1 1.3. Application Considerations ....................................................................................................... 1-4 1.4. Overcoming Contact Independence ......................................................................................... 1-6 1.5. Overcoming Contact Independence In Reverse Cab Applications .......................................... 1-7

2. EQUIPMENT DESCRIPTION ............................................................................................................ 2-1 2.1. Relay Wiring.............................................................................................................................. 2-1 2.2. Contact Current Ratings ........................................................................................................... 2-1 2.3. Isolation for Biased Solid State Relays ..................................................................................... 2-1 2.4. Voltage Requirements .............................................................................................................. 2-1 2.5. Temperature Range .................................................................................................................. 2-1 2.6. Indexing .................................................................................................................................... 2-1 2.7. Relay Wiring.............................................................................................................................. 2-2

3. INSTALLATION ................................................................................................................................. 3-1 4. OPERATION and TESTING .............................................................................................................. 4-1

4.1. Operation .................................................................................................................................. 4-1 4.2. Testing ...................................................................................................................................... 4-1

5. TECHNICAL SUPPORT .................................................................................................................... 5-1

List of Figures Figure 1-1. STS USA GRS-Style Code Responsive Relay ...................................................................... 1-2 Figure 1-2. N320030-09 Code Responsive Relay .................................................................................... 1-2 Figure 1-3. Indexing Plate ......................................................................................................................... 1-3 Figure 1-4. N320030-09 Indexing Plate .................................................................................................... 1-3 Figure 1-5. Steady Energized Relay (EMCRR) ........................................................................................ 1-6 Figure 1-6. Independent Contacts with ECRR .......................................................................................... 1-7 Figure 1-7. Reverse Cab Signal Application ............................................................................................. 1-8 Figure 2-1. Contact Block Viewed from the Rear of the Relay ................................................................. 2-2 Figure 4-1. Test Fixture for N32003001 through N32003008 Solid State Code Responsive Relay ........ 4-2


Copyright 2019 SM 9025 Rev. 45, March 2019 iv

List of Tables

Table 1-1. Configurations for the Solid State Biased Code Responsive Relay ........................................ 1-3 Table 1-2. Differences in Application of EMCRR and ECRR Relays........................................................ 1-5 Table 3-1. Wiring Connections to the Mounting Base .............................................................................. 3-1


Copyright 2019 SM 9025 Rev. 45, March 2019 1-1

1. INTRODUCTION

1.1. Glossary Coded Energy The signal that activates alternate closure of front and back contacts.

GRS General Railway Signaling (now part of Alstom).

Steady Energy The voltage applied to the relay so that back contacts alternately switch when coded energy is applied.

1.2. Description This service manual provides description and installation information for the Solid State Biased Code Responsive Relay (Figure 1-1 and Figure 1-2), Hitachi Rail STS USA’s solid state functional equivalent to the GRS/ALSTOM Type B Size 1 mechanical code responsive relay. This relay provides a solid state option for customers with existing installations utilizing the GRS/ALSTOM mechanical code responsive relays. Various combinations of low voltage and high voltage switches are employed in the design of these GRS-style relays. Model numbers are determined by the operating voltage and contact arrangement as listed in Table 1-1.

The STS USA Solid State GRS-Style Code Responsive Relay is comprised of a circuit board that contains eight solid state switches configured as four transfer front-back contacts. Because all of the switches are normally open, steady energy is required on one set of terminals to enable the back contacts. Applying voltage to another set of terminals activates the front contact switches and, in turn, causes the back set to open. If back contacts are not required, it is not necessary to enable them because the front contact switches will operate independently.

To ensure that the relay is inserted in its proper mounting base, all relays have indexing pins (Figure 1-3 and Figure 1-4). Relays lock securely in their plug-in position.

Wiring for the solid state relay differs from its mechanical counterpart. Coil connections to the mechanical relay are made on the lower portion of the mounting base. Corresponding connections for the electronic version are made on the upper portion with two additional termination points for steady energy.



SOLID STATECODE FOLLOWERUNION SWITCH & SIGNAL

12

8

16

4

20

24

30

91011

567

123

27

17

131415

32 31

1819

212223

2526

2829

33

CONTACT DESIGNATIONREAR VIEW

LOW VOLT.AC OR DC

AC ONLY

STDY._

+

_

+CODED

LABEL

CONTACTS

INDEXING PLATE

P/N

XXX

XXXX

XXX

S/N

XX

XXX

XXXX

GR

S S

IMIL

AR

X

XX

-XX

X

UG

0106

.000

2.00

Figure 1-1. STS USA GRS-Style Code Responsive Relay

3F2F

3H

3B

4F

4H

4B

2H

2B

1F

1H

1B

6

5

4

3

2

12

1

3

(+)

(-)

(+)

(-)

B_12

F_12

F_GND

B_GND

STEADY

CODEDHV AC

HV AC

HV AC/DC

LV AC/DC

HV AC

HV AC

LV AC/DC

LV AC/DC

CONTACT DESIGNATION-REAR VIEW

P/N

XXX

XXXX

XXX

S/N

XXX

XXXX

XX

GR

S SI

MIL

AR

XX

X-XX

X

SOLID STATECODE FOLLOWERUNION SWITCH & SIGNAL

123

6 5 4

789

12 11 10

131415

UG

0106

.007

2.00

Figure 1-2. N320030-09 Code Responsive Relay



Table 1-1. Configurations for the Solid State Biased Code Responsive Relay

Hitachi Rail STS USA

Part Number

Similar to GRS Relay

Input Voltage (Nom.)

Indexing Contacts

Contact Voltage Rating (VRMS)

Contact Current Rating (ARMS)

N320030-01 A62-598 12 1, 3, 9 2F2B - LV AC/DC 22 2.5 2F2B - HV AC ONLY 12-120 2.5

N320030-02 A62-157 12 1, 3, 24 4F4B - LV AC/DC 22 2.5 N320030-03 A62-156 12 1, 2, 13 2F2B - LV AC/DC 22 2.5

N320030-04 A62-595 12 1, 2, 18 2F - HV AC ONLY 12-120 2.5

2B - LV AC/DC 22 2.5 N320030-08 A62-622 12 1, 2, 9 4F4B - HV AC ONLY 12-120 2.5

N320030-09 - 12 1, 5, 11 2F2B - HV AC ONLY 12-120 2.5

2F1B - LV AC/DC 22 2.5 1B - HV AC/DC 100 0.3

12

8

16

4

20

24

30

91011

567

123

27

17

131415

32 31

1819

212223

2526

2829

33

123

6 5 4

789

12 11 10

131415

UG

0106

.007

3.00

Figure 1-3. Indexing Plate Figure 1-4. N320030-09 Indexing Plate



1.3. Application Considerations

NOTE

The Application Engineer must use the information provided in Table 1-1 to determine if the electronic code response relay can be substituted for the GRS electromechanical relay.

Other than the obvious difference that a steady energy supply must be used to duplicate operation of an electronic code responsive relay (ECRR) to its electromechanical code responsive relay (EMCRR) counterpart, there are other differences that need to be considered that relate to safety.

The differences between the ECRR and the EMCRR are listed in Table 1-2 with recommendation of prudent caution.

The original low-voltage contact voltage rating of the ECRR is not high enough for certain applications such as reverse cab signaling. The N32003009 GRS-style ECRR was created to provide a higher voltage rated low-voltage back contact for use on track circuits requiring reverse cab application.

Normally, the direction of travel is toward the transmit side of the track circuit. In this case, the cab is coded from the transmit side of the circuit. When direction of travel is reversed, the cab is coded from the relay end of the track circuit. When applying reverse cab signaling, it is common practice to open the circuit to the track occupancy device (TRU-II, Vane Relay, Electronic Vane Relay, TRU-III, etc.) with a back contact of the code follower as a front contact applies code to the rail.

WARNING

When using an ECRR in reverse cab signaling applications, the applied reverse cab signal must be referenced opposite that of the received train detection signal. Otherwise, there is a possibility of falsely energizing an associated TRU-III unit with the reverse cab signal. See Section 1.5 for more details and Figure 1-7 for an example implementation.



Table 1-2. Differences in Application of EMCRR and ECRR Relays

Characteristic EMCRR ECRR Recommendation or Comment

Calibration Pick-Up and Drop-Away are determined by the force generated by a magnetic structure and the restraining forces of contact springs and/or magnets. It is implied that pick-up and drop-away are thus assured.

Pick-Up and Drop-Away are primarily determined by photo-voltaic devices for which there is no implied guarantee that these parameters will never change. These devices have proven highly repeatable but calibration should not be regarded as absolute.

Do NOT use an ECRR in an application in which calibration is critical to safety. Note – in most applications this is not a factor.*

Contact Dependence

Contacts are driven by a common element and, therefore, a welded contact will prevent opposite state contacts from conducting.

Contacts are independent. A shorted contact, analogous to one that is welded, will not inhibit the others from functioning normally.

Do NOT use an ECRR in an application where dependent contact operation is critical to safety. (Examples of overcoming this problem are presented in Sections 1.4 and 1.5).

Inductive Load Switching

Preferred practice in switching inductive load relays is to snub the load to prevent arcing, EMI, and contact corrosion.

Transient protection is an integral part of the solid state switches.

External snubbing and arc suppression devices are unnecessary. Line-to-line and line-to-ground arrestors are recommended for circuits that exit the house or case.

Short Circuit Protection

A short circuit can damage the relay and could possibly initiate a fire in the wiring.

With the low voltage contacts, a short circuit will cause no damage to the wiring or the ECRR.

There should be less concern about short circuits with the ECRR.

Code Following Integrity and Reliability

Contacts open and close substantially matching the ON time of the code but erode with time; this causes code ON time distortion and eventually contact failure. The rate of contact failure is accelerated at higher code rates and contact loading. In cab signal applications, the point on the waveform of circuit interruption is random.

Code ON time is more consistent. There is no wear out mechanism and, therefore, no degradation of performance regardless of code rate and contact loading. In cab signal applications, the point of circuit interruption occurs at the zero crossing resulting in less harmonic noise generation than would otherwise occur.

For those applications where the code follower is repeating ON-OFF switching from a code generator, the ECRR is a superior device.

*Low resistance coil relays generally used as track relays are examples where calibration is critical to safety. Relays discussed in this manual are not suitable for that or similar applications.



1.4. Overcoming Contact Independence In some safety critical applications, a vital relay is steady energized proving that the EMCRR is following code. The general way in which this is accomplished is illustrated in its simplest form in Figure 1-5.

EMCRRA

AFP

ABP

AFP ABP

AP

snub

snub

Figure 1-5. Steady Energized Relay (EMCRR) A snub on AFP and ABP delays drop-out for sufficient time so that AFP and ABP remain steady energized as long as A is following code. When coding stops either AFP or ABP drops as does AP. This technique is valid with EMCRR’s because a front and back contact cannot simultaneously be closed. The contacts are not independently driven. This technique is not valid for the ECRR because the contacts are independently driven and can be simultaneously closed. The same function can be accomplished with an ECRR in one of the two ways shown in Figure 1-6.

Circuit A of Figure 1-6 uses a single transfer contact and diodes to achieve a voltage negative with respect to N12; circuit B accomplishes the same function with marginally better efficiency using two transfer contacts. In either case, AP, which must be a biased neutral relay, will energize when A is following the code. It is a vital mechanism that ensures AP will deenergize when A is not following the code. It overcomes the problem inherent with ECRRs that shorting of front and back contacts together is a possibility. The circuit elements to duplicate these circuits are packaged on a printed circuit board that is compatible with relay rack mounting. The PCB for the GRS B1 relays is part number N39903801, and the one compatible with the STS USA PN-250 style relays is N39903701.



AP

B12

N12

ECRR

A+

+

+

__

_

CKT A

AP

B12

N12

ECRR

A

+

++

_

_

_

CKT B

A

Figure 1-6. Independent Contacts with ECRR

1.5. Overcoming Contact Independence In Reverse Cab Applications To use an ECRR in reverse cab signal applications, the application designer must use certain rules due to the possibility of a failure mode when the high voltage front and low voltage back contacts are closed at the same time. This failure could cause the cab signal to provide coded energy to the track occupancy relay.

See Figure 1-7 for details. Notice the connection of NX110 to 1A of the TRU-III. By referencing the applied reverse cab signal opposite that of the received train detection, the possibility of falsely energizing the TRU-III unit with coded energy is eliminated. If



the front and back contacts were to become a short circuit, the phase of the reverse cab signal would be opposite that of the TRU-III local reference signal.

RESET

N12

B12

1E1F(-) (+)

(-)

(+)

100 100

TRU III1A 1B

1C 1D

10

:110

:1

BX110

BX110

NX110

NX110

CFR

CFR

3K1.

0020

.01

W E

CFR EVSREVSR

1/2

3/4

9/1011/12

13/14

15/16

TO TRACK RELAY (TR)OR

PROCESSOR

TO RELAY OR PROCESSOR

Figure 1-7. Reverse Cab Signal Application



2. EQUIPMENT DESCRIPTION

2.1. Relay Wiring For the solid state relay, coded energy and steady energy are connected to terminals on the contact block (Figure 2-1). Coded energy can be wired in parallel with coded energy normally applied to the lower connections on the mounting base. Steady energy wiring must be added to the contact block terminals. If the wiring is done in this manner, it is possible to interchange the solid state relay with the electromechanical relay.

2.2. Contact Current Ratings Low voltage switches support AC or DC load currents to 2.5 amperes at 30 volts DC or 22 volts RMS up to +70°C. They are transient protected to 34 volts.

For high voltage applications, the switch is an AC only device. The contact load rating is from a minimum hold current of 0.06 amperes to a maximum of 2.5 amperes from 12 to 120V rms. High voltage contacts are protected up to 230V rms but are not short circuit protected. An external fuse is required for short circuit protection of high voltage AC only contacts.

The N32003009 ECRR was created to provide an AC/DC back contact with a higher voltage rating of 0-100V RMS @ 300mA for reverse cab signal applications in the TRU-III track circuit applications.

2.3. Isolation for Biased Solid State Relays The steady power source and code input are isolated. Contacts and inputs are isolated from each other and the frame. The withstand voltage is 1500V rms. Breakdown voltage across a front-back contact set is limited by the surge protection ratings of 34V for low voltage contacts and 130V rms for high voltage contacts.

2.4. Voltage Requirements Operating voltage is 8 to 16VDC. Ripple must be limited so that the instantaneous voltage does not dip below 8 volts. A nominal 12 volt battery/battery charger combination is a suitable power source.

2.5. Temperature Range The solid state relay will operate over a temperature range of -40°C to +70°C.

2.6. Indexing The STS USA GRS-style solid state relay is indexed the same as the electromechanical relay it replaces except it uses only the first three index holes. Refer to Table 1-1 for the index code. Figure 2-1 shows the contact block as viewed from the rear of the relay. The N32003009 STS USA GRS-style ECRR is indexed uniquely to deter misapplication.



2.7. Relay Wiring The relay is wired as shown in Figure 2-1.


LOW VOLT.AC OR DC

AC ONLY

STDY._

+

_

+CODED


LOW VOLT.AC OR DC

STDY._

+

_

+CODED


LOW VOLT.AC OR DC

STDY._

+

_

+CODED


LOW VOLT.AC OR DC

STDY.

_

+CODED

N320030-01 N320030-02

N320030-03 N320030-04


HIGH VOLT.AC ONLY

STDY._

+

_

+CODED

N320030-08 N320030-09

AC ONLY

_

+

UG

0106

.000

4.01

2F 3F

2H 3H

B_GND 2B 3B

B_12 1F 4F

F_GND 1H 4H

F_12 1B 4B

123

1

2

3

4

5

6

STEADY

CODED

(+)

(-)

(+)

(-)

CONTACT DESIGNATION - REAR VIEW

LV AC/DC

HV AC/DC

HV AC

LV AC/DC

LV AC/DC

HV AC

HV AC

HV AC

Figure 2-1. Contact Block Viewed from the Rear of the Relay



3. INSTALLATION

This solid state relay can be installed in the same mounting base as the GRS/ALSTOM Type B Size 1 mechanical code responsive relay. The relay is shipped with a female index plate that can be installed on the mounting plate for the solid state relay.

To install the solid state relay, steady 12-volt power must be wired to the mounting base to provide steady energy to the solid state relay. The required steady energy and coded energy connections to the base are shown in Table 3-1 (refer to Figure 2-1 for the relay wiring).

Table 3-1. Wiring Connections to the Mounting Base

Signal Mounting Base

Column Row +12 Volts 3 3 -12 Volts 3 4

+Coded Energy 3 1 -Coded Energy 3 2

Prior to inserting the solid state biased code responsive relay in the mounting base, the installer must ensure that the mounting base is wired per Table 3-1 to ensure proper operation of the relay.



4. OPERATION and TESTING

4.1. Operation No periodic testing or adjustment is necessary. There are no calibration or adjustments required on the solid state relay. The output switches are MOS FET devices (or Triac devices) that are controlled by switching logic elements in the solid state circuitry.

4.2. Testing Testing a solid state relay differs slightly from testing an electromechanical relay. A minimum operating voltage replaces the pick-up calibration. Testing consists of energizing the relay with 8VDC and observing that the contacts close. Since both the high voltage and low voltage contacts will operate on AC voltage, an AC source is used to indicate contact closure.

To verify the operability of the relay, connect it to a test fixture wired as shown in Figure 4-1.

Apply the AC power by closing SW 1. No lamp should be illuminated. Any lighted lamp indicates a shorted switch.

Close SW 2. Lamps, 1B, 2B, 3B, and 4B should illuminate. Any lamp not illuminated indicates an open switch. (This assumes that the indicator lamps are intact. If a lamp is not illuminated, the bulb can be checked by shorting the front or back contact wire to the heel contact wire. With this short the bulb should light.)

Close SW 3. Lamps, 1B, 2B, 3B, and 4B should extinguish, and lamps 1F, 2F, 3F, and 4F should illuminate. Any lamp not illuminated indicates an open switch. (This assumes that the indicator lamps are intact. Check the bulb per Step 2 if it is not illuminated.)

If the test results are satisfactory, the relay test is complete. Return all switches to their "off" position.

If the relay fails the test, STS USA recommends returning the relay to STS USA for repair.

To test the N32003009 ECRR refer to STS USA Test Specification N32003009.S06.EN.



LM7808

+

_

TO 120 VAC LINE

SW1 F1 T1

C1+

1F

2F

3F

4F

1B

2B

3B

4B

SW2

SW3

1 6

1 3

2 6

2 3

1 4

1 1

2 4

2 1

1 5

1 2

2 5

2 2

3 3 (+ STEADY ENERGY)

3 4 (- STEADY ENERGY)

3 1 (+ CODED ENERGY)

3 2 (- CODED ENERGY)

T1: TRANSFORMER, 120 V AC TO 12 V AC, 2 AMPERES OR BETTER1F - 4F1B - 4B

: LAMPS, #1891, 1892, OR 1893

D1: BRIDGE RECTIFIER, 100 VOLT, 5 AMPERESW-1, 2, 3: SPST SWITCH

MISC: LAMP SOCKETS, WIRE MOUNTING BASE, AND RECEPTACLES

C1: 100 MFD, 50 VOLTF1: 120 VOLT, 3 AMPERE FUSE, AND HOLDER

LM7808: 8-VOLT VOLTAGE REGULATOR

COLUMNROW

Figure 4-1. Test Fixture for N32003001 through N32003008 Solid State Code Responsive Relay



5. TECHNICAL SUPPORT

The Rapid Action Information Link Team (RAIL Team) is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product. Contact the RAIL Team at 1-800-652-7276 or by e-mail at [email protected].

mailto:[email protected]



End of Manual

solid state grs/alstom style biased code responsive relay · responsive relay. this relay provides...

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