SM-3623A

SM-3623A
IUNION SWITCH & SIGNALllfil]
645 Russell Street
Batesburg, SC 29006
Service Manual 3623A
KP Relays
Installation, Operation and Maintenance
August, 1961
B0.61-200-8.61.3
© 1961, Union Switch & Signal Inc.
Printed in U.S.A.
An Ansaldo Signal Company
UNION
SERVICE
SPECIFICATION
SU-3623-A
NUMBER
UNION SWITCH & SIGNAL ••••• SWISSVALE, PA.
DIVISION
OF
WESTINGHOUSE
AIR
BRAKE
COMPANY
MA5rER SERVICE SPECIFICATION
FOR OVERHAUL OF KP RELAYS
*************•******
Where only calibration adjustments are made, use Servke Specification
SU-3623.
THIS SPECIFICATION MUST ·BE USED IF KP RELAY OVERHAUL INVOLVES DISASSEMBLY OF THE OPERATING PARTS SUCH AS WOULD BE
NECESSARY WHEN ONE OF THE OPERATING COMPONENTS IS REPLACED.
SUCH DISASSEMBLY MU5r BE DONE ONLY BY ORGANIZATIONS WHICH ARE
COMPLETELY EQUIPPED WITH THE SPECIAL FIXTURES, GAUGES, ETC.,
WI-IlCH ARE ABSOLUTELY NECESSARY TO THE CORRECT REASSEMBLY OF
THE RELAY.
This is a master specification for overhaul of all types of "KP" relays and
contains only information common to the various types. For specific information
concerning each type, refer to the following supplementary service specifications:
Stick Type
Standard Biased Type
Special Biased Type
Service Specification SU-3623-Al
Service Specification SU -3623-A2
Service Specification SU -3623-A3
INDEX
Section
Page
I. Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II. Assembly . . .· . . . . . . . . . . . . . . . . . . .
III.
IV.
V.
VI.
Contact Adjustment
Permanent Magnets
General Inspection .
Final Inspection. . .
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1
2
4
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5
5
I. ROfOR
If the rotor has been damaged, other than by minor bending of springs, it
should be replaced. Ordering references for complete rotor assemblies are given
in the supplementary service specifications covering each type of relay.
Before it is assembled to the relay, each complete rotor assembly should be
inserted in inspection fixture tool No. T-35154 and the adjustment of the contact
August 1961
80.61-200-8.61~3
Printed in U. S. A.
m
u. s. & s.
- 2 -
Service Spec. SU-3623-A
springs and flexible connectors checked and, if necessary, adjusted. If any change
of more than 0. 005 inch is necessary, it should be adjusted and baked at 240° F
for six hours, or at 200° F for fifteen hours and then rechecked after baking.
II. ASSEMBLY
(a) Place the contact frame in position on inspection fixture No. T35202 and
adjust the contact members both vertically and horizontally so that the contact
buttons just touch the spacer in the fixture. Contact adjustingtool, Pc. UM243059A2586-Sh. 68 has been specially designed for this purpose. Stamp the piece
number of the re lay to be assembled on the top rear surface of the contact frame.
{b) Assemble the front trunnion bracket to the contact frame as shown in
Figure 3. Observe that the screw heads do not extend beyond the front of t.he
· contact frame.
(c) Assemble the rotor, coils, and yokes to the contact frame as shown in
Figure 3 without fastening the yokes tightly. If the fit between coils and yokes is
too tight, the coil notches should be filed just enough to avoid a force fit.
Place the rear trunnion bracket in position and with it held firmly against
the contact frame, observe, by means of a dial indicator, that the rotor has
from 0.005 inch to 0.010 inch end play between the front and rear trunnions. If
the end play is less than 0.005 inch, it may be increased by applying spacer
washers under the rear trunnion bracket as shown in Figure 3. Also observe
that there is at least O.015 inch clearance between the rotor hub and each coil
as called for in Figure 3.
(d) Insert adjusting tools, Pc. UN242994-A2586-Sh. 63 in the slots provided
at each end of the contact frame. Hold the yokes firmly against these tools and
fasten yokes tightly in position.
(e) Remove the adjusting tools and place fully charged magnets is position
and see that the armature takes either extreme position. With the rotor held in
positionagainst one pair ofpole faces, fix thepositionof the reartrunnion bracket
by pouring 7% antimony lead into the holes provided. All stop pins should now
touch their respective pole faces when the armature is in either extreme position. If any stop pin is more than 0.002 inch away from its pole face when the
opposite stop pin is seated, the rear trunnion should be relocated.
(f) Fasten the flexible heel connectors to their frame supports by means of
eyelets and then solder. The solder should not run beyond the ends of the supports. All soldering on these relays should be done using a non-corrosive solder
flux. We recommend that solder with a resin -5 core be used. Immediately
after a solder connection is made, the soldered area should be cleaned with a
clean dry cloth moistened in alcohol.
With the permanent magnets removed, the armature should now take a central position with respect to the pole faces. If the armature is off center, the
brass members to which the heel connectors are attached .should be bent until
u. s. & s.
Service Spec. SU-3623-A
- 3 -
the armature takes a central position with respect to the pole pieces. The bending should be distributed among all members. In no case should the heel connectors themselves be bent.
(g) Before soldering, form each coil lead into a loop as follows: Where the
lead enters the coil, bend it away from the coil end of a I /8 inch radius and then
form it in a circular loop about I /4 to 3/8 inch in diameter as shown in Fig. 1.
II
II
1
3
4 TO a DIA.
~
II
RADIUS
----:1..-t:~---.. . . --
FIGURE 1
(h) After the relay is assembled, but before the application of the permanent
magnets and before heat treating, apply red glyptal enamel UA40266, to the back
of the relay in eight places, (as shown in Fig. 2) in order to prevent coil movement under vibration conditions. The enamel should be applied on the outside end
0
0
.....,_.__.-RELAY
CONTACT
FRAME
....---.---YOKE
....,..IE.f--11----
COIL
.......----+-- TRUNNION
REAR
0
0
XXXX - Red Glyptal Enamel, UA40266
FIGURE 2
U.S. & S.
-4 -
Service Spec. SU-3623-A
of both coils between the yokes and the end of each coil including one edge of the
yoke mounting screws and also, between the inside end of each coil and each side
of the rear trunnion.
The consistency of the glyptal enamel should be watched carefully. If it becomes "stringy", it is too thick and must be thinned, using a special thinner,
UA40172.
.
If it is too thin, it will run through and will, therefore, not perform the intended function of holding the coils firmly in place.
Ill. CONT ACT ADJUSTMENf
(a) Contacts of various types of relays are adjusted differently to produce .
different characteristics. This is done by inserting the proper contact adjusting .
fixtures firmly into the air gaps at both ends of the relay, thus holding the position of the rotor, and then adjusting the fixed contacts so that their contact buttons
just touch corresponding contact buttons on the flexible contact members. Contact adjusting tool, Pc. UM243059-A2586-Sh. 68 has been specially designed for
this purpose. In no case shall flexible contact membersbe adjusted to align contacts. The contact adjusting fixtures to be used, the deviation permitted from
perfect contact adjustment, the heat-treatment required, and the contacts to be
adjusted with- the adjusting fixtures in a given position are given in the supplementary specifications covering each type of relay.
For stick type KP relays, the contacts which are compressed when the rotor
is turned to the clockwise position (as viewed from the front of the relay) are
designated "normal" contacts and the contacts which are compressed when the
rotor is turned counterclockwise are. designated "reverse" contacts.
For biased type KP relays, the contacts which are compressed when energy
is applied to tum the rotor to the clockwise position (as viewed from the front of
the relay) are designated "front" contacts and the contacts which are compressed
when no energy is applied to the relay (rotor in the ·counterclockwise position)
are designated "back" contacts.
IV. PERMANENf MAGNETS - ADJUSTMENf AND CALIBRATION
(a) Permanent magnets should be assembled to the relay with the poles marked "N" to the right as viewed from the front of the relay. The poles marked "N"
should attract the end of a magnetic compass which points toward geographic
South.
(b) Relay calibration is finally determined by adjusting the strength of the
permanent magnets. A pair of magnets should be placed over the coils of a relay to check if they seat squarely against the yokes. They should then be charged
to full saturation, and each magnet partially demagnetized by applying a convenient value of alternating flux to the magnets. If a magnet is discharged too far,
it should again be charged to full saturation and discharged with a slightly lower
value of alternating flux. The permanent magnet strength may be adjusted using
the magnet charger described in Instruction Pamphlet U-5455.
U.S.&S.
- 5 -
Service Spec. SU-3623-A
(c) For calibration, refer to the individual supplementary specification.
(d) The magnets should be assembled to the relaywith like poles in the same
direction so that, with the relay in the normal operating position and with positive
energy applied to the left of either coil, the armature will rotate to the clockwise
position as viewed from the front of the relay.
(e) In taking calibration, the energizing circuit should be opened for one
second before reading the pick-up value, and the relay energized to four times
maximum pick-up before reading the drop-away value.
V. GENERAL INSPECTION
{a) A general inspection of the contacts shall be made after adjustment to
see that they are properly aligned and meeting squarely. The relay calibration
should then be checked. Slight adjustment of the fixed contact members should
be sufficient to adjust the calibration.
(b) It should be noted that all lock washers are used where required, and
that they are fully compressed.
(c) The coil leads should be arranged so that they cannot vibrate into such a
position as to interfere with operation of the contacts.
(d) Flexible connectors should be examined to see that they are formed to
give adequate clearances and are properly soldered.
(e) The tag should be marked with the Code No. and Serial No. of the relay,
together with date and inspector's initials. This tag should be inserted in the
bottom of the relay as shown in Figure 3.
(f') A careful inspection should be made to be sure that all dirt and foreign
matter has been removed from the mechanism, paying special attention to air
gaps and contact surfaces.
VI. FINAL INSPECTION
(a) The front cover and back cover should be carefully assembled so that all
gaskets lie smoothly and are compressed, sealing the relay tightly, observing
that the gasket does not extend beyond the edges of the relay.
(b) After sealing, the relay should be examined through the cover to see that
contacts, flexible connectors, and coil leads have not been misplaced since calibration.
(c) A final check of relay calibration should be made.
- 6-
U.S.&S.
Service Spec. SU-3623-A
REAR
GASKET
PERMANENT
MAGNET
BRACKET
FILL WITH 7
%
ANTIMONY LEAD
SPACER WASHERS
( AS REQUIRED)
FRONT
YOKE MOUNTING
SCREWS
COVER
SECURE COIL USING
RED GLYPTAL ENAMEL
APPLIED PER FIG. 2
TAG
FIGURE 3
YOKES
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