Section

I

II

III

SERVICE_ MANUAL

ION AND MAIN

INTRO DU

1.1 PTION 1.2 ING CHARACTERISTICS

1.2.l Input Voltage 1.2.2 Output Voltage

PROTECTIVE CIRCUITS

2.1 OVERLOAD PROTECTION 2.2 TRANSIENT VOLTAGE PROTECTION

MAINTENANCE

3.1 CORRECTIVE MAINTENANCE 3. 2 PREVENTIVE MAINTENA..°f\JCE

3.2.1 Electronic Circuit Board D451034-1201

3.2.2 Output Section 3.2.3 Pre-regulator Section

Page

3

3 3

3 4

5

5 6

6

6 6

6

7 8

May, 19 74 B-74-200-1034.3

WESTINGHOUSE AIR BRAKE COMPANY UNION SWITCH & SIGNAL DIVISION Swissvale Post Office, Pittsburgh, Pa. 15218

An American-Standard Company

Section

Figure

1

2

3

4

5

6

7

TABLE OF CONTENTS (CONTINUED}

3.2.4 Complete Converter

3.2.4.1 3.2.4.2

32 VDC and 350 VDC Converters 64 VDC Converter

LIST OF ILLUSTRATIONS

Schematic Diagram, Converter N451033-0201 and N451033-0202

Schematic Diagram, Converter N451033-0203

Wiring Diagram, Converter N451033-0201 and N451033-0202

Wiring Diagram, Converter N451033-0203

Parts List, F-40 Converters

Parts List/Locator, F-40 Converters

Outline Diagram, F-40 Converters

SM-5 7 7 8, p. 2

Page

8

8 11/12

Page

13/14

15/16

17/18

19/20

22

23/24

25/26

SECTION I

INTRODUCTION

1.1 DESCRIPTION

The F-40 Converter is a solid state DC to DC converter de­veloped for general use as a power supply unit in train control systems. It is designed to replace motor/generator sets used in existing train control installations. The F-40 Converter basically consists of an electronically controlled pre-regulator and an inverter with rectified and filtered outputs.

Two single output units are available, N451033-0202, which produces 32 VDC (see schematic diagram of Figure 1) and N451033-0203 which produces 64 VDC (see schematic diagram of Figure 2). A dual output unit is also available, N451033-0201, which produces 32 VDC and 350 VDC (see schematic diagram of Figure 1).

These units are designed to operate continuously in ambient temperatures of -300F to +1600F, with excursions to -40°F causing no equipment damage.

Electrical connections are made to a terminal board mounted behind a standard junction box on the front side of the converter. The input and output cables use a common "cable connector" which locates along side the junction box cover. Input and output circuits are completely isolated from each other and ground.

W,:\BCC ~

The converter displaces less than 1 cu. ft. and can be mounted either horizontally or vertically on 7-3/8" centers with 3/8" bolts. For mounting details, see the outline diagram of Figure 7.

1.2 OPERATING CHARACTERISTICS

1.2.1 Input Voltage

Input voltage can vary from 64 VDC to 80 VDC with a nominal value of 72 VDC. Once the converter is operating, input voltage can drop to 45 VDC without damage to the unit.

SM- 5 7 7 8 , p • 3

WAl;:ICC ~v

1.2.2 Output Voltage

Three output voltage levels are possible, depending upon which converter is installed:

A. 32 VDC--this level will hold within the range of 30.4 VDC to 33.6 VDC under a varying load of from Oto 4 amperes and the full ambient temperature range. Once operating, output voltage will hold above 27VDC if the input voltage drops to the 45 VDC level (minimum level without equipment damage) .

The 32 VDC output from either the N451033-0201 or the N451033-0202 converter is capable of starting with a lamp load of four, 15 watt signal lamps in multiple a.s part of the normal load.

Ripple voltage does not exceed 2.5% maximum.

B. 64 VDC-·-this lever will hold within the range of 60.8 VDC to 6 7. 2 VDC under a varying load of from O to 2 amperes and the full ambient temperature range. Once operating, output voltage will hold above 54 VDC if the input voltage drops to the 45 VDC level (minimum level without equipment damage) . ·

The 6 4 VDC output from the N4510 33-0 20 3 converter is capable of starting with a lamp load of four, 15 watt signal lamps in multiple as part of the normal load.

Ripple voltage does not exceed 2.5% maximum.

C. 350 VDC--this level will hold within the range of 325 VDC to 350 VDC under a load of 0.1 amperes and varies according to the adjustments necessary to obtain the 3 2 VDC output. However, this voltage level is not critical to the adjustment.

Ripple voltage does not exceed 2.5% maximum.

SM-5 7 7 8 , p • 4

SECTION II

PROTECTIVE CIRCUITS

2.1 OVERLOAD PROTECTION

WABCQ ~

Protective circuits are incorporated into the converter design for overload protection for each of the three possible outputs:

A. 32 VDC--this output is not fused but is "self-protected" in that a short circuit will "stop" the magnetic oscillator and can remain shorted indefinitely without damage to the unit. If a short circuit has occurred, the converter can be restarted by opening the input circuit and reclosing after at least a 5 second delay.

3 A 43V ±5% zener diode is provided across the pre-regulator output (2000uf-50V capacitor) circuit. This diode will 11 short out II on over-voltage and, thus, prevent high volt.,.. age from being applied to the output circuits.

A 7-1/2 ampere fuse is provided to protect the inp~t circuit.

B. 6 4 VDC--this output is not fused but is "self-protected" in that a "short circuit" will "stop" the magnetic oscillator and can remain shorted indefinitely without damage to the unit. If a short circuit has occurred, the converter can be restarted by opening the input circuit and reclosing after at least a 5 second delay.

A 43V ±5% zener diode is provided across the pre-regulated output (2000uf-50V capacitor) circuit. This diode will "short out" on over-voltage and, thus, prevent high volt­age from being applied to the output circuits.

A 7-1/2 ampere fuse is provided to protect the input circuit.

C. 350 VDC--this output incorporates the "self-protection" feature of the 32VDC and 64VDC outputs (see paragraphs A and B). In addition, a 1/8 amp fuse (3AB, vibration proof) is used,because of conductor limitations, to protect against partial short circuits.

A zener diode and 7-1/2 ampere fuse act to protect the output circuits in the same manner as those used in the 32 VDC output (see paragraph A).

SM-5778, p. 5

2.2 TRANSIENT VOLTAGE PROTECTION

The converter input is designed to withstand a surge of 1250V line­to-line for 300 to 400 microseconds and a 3000 VAC dielectric test between input and output terminals and between the input and output terminals and the case.

A diode is placed across the input circuit to prevent a reverse polarity application and also to suppress inductive transients that occur on the battery line when the battery is disconnected.

SECTION III

MAINTENANCE

3.1 CORRECTIVE MAINTENANCE

Corrective maintenance should be performed only after the area of failure has been established. section 3.2 (Preventive Maintena:r:i-ce) consists of test procedures to check the integrity of the electronics circuit board, the output section, the pre-regulator section, and the complete converter. After determining to which section a failure is confined, refer to the appropriate schematic, drawings, wiring diagrams, and parts list/locator of Figures 1 to 5 ;for troubleshooting and repair see LIST OF ILLUSTRATIONS, page 2, for identification of appropriate material . If failures cannot be isolated in this manner, or if so desired for other reasons, malfunctioning units may be returned to WABCO for repair and/or calibration.

3.2 PREVENTIVE MAINTENANCE

3. 2 .1 Electronic Circuit Board D4510 34-1201

Perform the following checks to assure that the Electronic Circuit Board is functioning properly.

1. Place a 2.SK, 2W, Pot. across terminals #1 and #2.

2. Attach a variable Power Supply across terminals #1 (+) and #5 (-). The maximum voltage should not exceed 35V and the current requirement should be less than lOOma.

3. Adjust input voltage slowly to 35V and note that the current is less than 65ma. The actual value will vary with the Pot. setting.

SM-5778, p. 6

4. With the input voltage held at 35V, slowly rotate the 2.SK Pot. until a point is reached that switches Q4 "on" and "off" with slight rotation of the Pot. The voltage differential must not exceed O.SV. This "switch point" must fall within the range of the 2.SK pot. Failure to meet this test is an indication that the Reference Diode (Dl) is not within the '±5% range or other components are of improper value. Inspect the balance of the control board in relation to the state of Q4 as follows:

Q4 Q3 Q2 Ql

on off on off

off on off on

3.2.2 Output Section

Perform the following checks to assure that the output section is functioning properly.

1. Disconnect the .Red (#14) lead (Q8-E) from the 2000m.f. capacitor (C6). This separates the pre-regulator from the converter output section.·

ALL OUTPUTS TO BE ON OPEN CIRCUIT.

2. Connect a variable D.C. power supply (approx. lA capacity) across the Red lead (item 1) and the -D.C. input terminal. Place a frequency meter and scope across the +lS and 2S leads of the out­put transformer.

3. Slowly increase the input voltage from Oto 10 volts and note that the output wave form of the output transformer (1S-2S) is a symmetrical square wave without spikes. The input current should not exceed 200ma at this point.

4. If Item#3 is satisfactory, increase the input voltage to 35V. The converter section should meet the following table of values.

SM-5778, p.7

WAEICCJ. 'V'"A/'

DC Input

v A

35 .40 ±2%

TABLE I

32 VDC 64 VDC output Output

v A v

34.6 0 65.5 ±1% ±1%

350 VDC Frequency Output

A v A Min. Max.

0 400 0 360 440 ±1%

3.2.3 Pre-regulator Section

Perform the following checks to assure that the pre-regulator section is functioning properly.

1. Separate the converter section from the pre­regulator section as per Item 1 of Section 3.2.2.

2. Place a D.C. Voltmeter (0-50) across the terminals of C6 (2000m.f.) and a 0-lOOVDC variable power supply {lA capacity-Approx.) across the+ and - input terminals.

3. Slowly increase the voltage from O and note that the output voltage is rising with the input voltage. At 36V, adjust the control potentiometer (R24) to give 35V output and note that the series switch is operating (Reactor noise). Recheck from OV and note that the output voltage does not rise above 35V with input range of Oto 45V. The input current should be approximately soma at this point.

4. Gradually increase voltage to +80 and note that the Output Voltage remains essentially 35V. The input current should be approximately 80 ma at this point. This current value will vary slightly with component variations.

3.2.4 Complete Converter

Perform the following checks to assure that the complete converter is functioning properly, following the instructions of the following Step 1 for calibration.

3.2.4.1 Calibration and tests for 32 VDC and 350 VDC Converter

The complete converter should meet the following tests within the tolerances specified.

SM-5 7 7 8 , p • 8

1. Calibration at Room Temperature.

With 72 VDC applied to the input terminals adjust the 11 32V" output by means of potentiometer (R24)

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~ ...... "'

to read exactly 32V with a 2A resistive load applied. The meters used should not exceed 1% accuracy. Also, the voltmeter used for calibration purposes should also be used to meter this output on the following tests, in order to minimize the voltage spread.

"Lock R24 in its calibration position".

2 • Load Tes ts

The "32V" output load should consist of 4 - (34V-15W) Lamps , CN71410, in multiple, with resistance as required. The "350V" Output load must be resistive. The unit must start, under full load, with from 64 to 80 volts applied at any temperature between -300F and 1600F. (The starting time may be as long as 3 seconds at -300F).

SM - 5 7 7 8 , p • 9

WRBCCJ 'V'"4'V'

Test

D.C.

TT v

64

64

64

64

72

80

80

80

80

Values as follows:

TYPICAL VALUES - 1% METERS

AT 30°C

Optional Input 32 VDC Output 350 VDC Output

** * A v A v A

0. 35 32.9 0 382. 0

0.99 32.8 0 342 0.1

2.72 31.1 4.0 373 0

3.45 31.0 4.0 335 0.1

1. 4 32.0 2.0 377 0

0.3 33.0 0 382 0

0.8 32.8 0 342 0.1

2.2 31. 3 4.0 376 0

2. 72 31.1 4.0 337 0.1

* This output will vary with calibration (R24)setting but should never be less than 325V fully loaded.

** The maximum swing permissable is 30.4V to 33.6V (no load to full load) for any ambient temperature between -30°F and +1600F.

SM-5778, p. 10

3.2.4.2 Calibration and Tests for 64VDC Converter

The complete converter should meet the following tests within the tolerances specified.

1. Calibration at Room Temperature.

With 72VDC applied to the input terminals adjust the "64V" output by means of potentiometer (R24) to read exactly 64V with a lA resistive load applied. The meters used should not exceed 1% accuracy. Also, the voltmeter used for calibration purposes should also be used to meter this output on the following tests, in order to minimize the voltage spread.

"Lock R24 in its calibration position."

2. Load Tests

The "64V" output load should consist of resistance as required. The unit must start, under full load, with from 64 to 80 volts applied at any temperature between -300F and 1600F. (The starting time may be as long as 3 seconds at -300F).

Test Values as follows:

TYPICAL VALUES - 1% METERS AT 300C

o.c. Input 64 VDC Output

v A v 64 0. 35 65.5

64 2.72 62.5

72 1.4 64

80 0.3 65.5

80 2.2 63. 0

Ripple l.25V P-P maximum at Full load Pre-regulated Voltage--34.5V

A

0

2A

lA

0

2A

SM-5778, p. lt/12

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SM-5778, p. 13/14

INPUT NOYttu.L

72VDC

UHZl 1711-001

2

' c• ... Z 200V

FUS IBLE RESISTOR

•• 100

01 fN97t

•

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#14 RED WIRE TO BE ftEUOVED FROM Cl- I

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DUR I NG CONVERTER OUTPUT TEST.

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

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NOTE: CA,.AC I TORS - WO } RESISTORS - 111 UM.ESS NOTED.

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INDICATES STANDOFF" TUfUIET (SOf..HR)

INDICATES CIRCUIT BOAND C<>iNJCCTI'* OR COMl"ONENT TEMIINAL,

• - CONV(RTOR OUTPUT TUIT ,.0 I NTS,

Figure 2.

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------ 17- - - ----- -- -

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: ~ .. : = "

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Schematic Diagram, Converter N451033-0203

... 1 800- 1

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Cl

500 IOOV

64V DC

SM-5778, p. 15/16

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SM-5778, p. 8

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SM-5778, p. 19/20

PARTS LIST

FOR

F-40 CONVERTERS

WAl:ICC "-'l"+'V'

SM - 5 7 7 8 , p • 21

WABCC

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3 3

z • B

._±__ c.±... 4 + 4 + 12 ,. I

3

9 2.

' L "' "' 18

... •• 67

•a

"' 20. 11 7Z , .. 7.~.

UJ470BI 8078 I 1!113 ~IISJt«T

U.TS070Z.S SG:R£W, •s-.32JII. ~ 8nvD1Nti .$T=;!_! ... _

u7SZSO~'~"----i=S~c~··~w~,~~-·~-~·~o~·~,.... .... ~~~D-~S~T~·~··~~:......_j~ IJJ477toS WA5ff£1, *4 .. oc:'°'" .sr"-· Tp ~

UJ?Zfl6!_ _ .90t.S f33 ~~.51ST01t ,_ZQ()·ONlrlS, .!W

7$ ,. l-'-+~+'--t·=-FV=J,•=~IZ00-0101 '(_"-312.00 01 LABEL. I I UN'1SI034-34f!2 C46IO~<f.. 3..,_ ,Bo,,i,eo, Plf.1-c.1111

;o I~ ~o ;: ~~:::,:~- :::~:~-;;; ==~- '"~:~: T;r~. ~~ e z. ,., uJ5vs,, Sce1o.w, •1o<J2 K J/8 e,1.,.1).ST .... .,. ~.

Parts List, F-40 Converters (to be used in conjunction with Figure 6.)

SM-5778, I?· 22

SPCC CHl'ISSIS I TltRN.SFOll1"'£R 8 CRP. 'C1 ,. RES."lfi!S"

EU· F,f.5103 "I ,,., Df-5/039 l'IMT N.O, Vlll~tN<: DIA<:. li~MAlfXS

SH. M•Q l"lllfTN.O.

0201 5f7f UR45/03f·030/ 3 1/N<ISJtHS-oJOI .3 l}J702.0"8 <1s1q33-050/ IJL..,.5/0U- . ., 0202 54-71 UR,,51034·030/ 3 N'IS!03S·0301 3 t1JJOZ.Of.8 JJL.,.5/033-0ifOI IU JNl,.IAI II:. v,rw "y 0203 5716 flR'fSl()J<f-·tnoz. 3 11114'-SIOJS·OJO~ • 1#91f.S·DOZI. ... 1$5SIJ·O(Jft BOO uc'ISIZl"-o•oJ Ut.'ISJ28l·08o If$ rll/<JWIJl/l:.VflW"'f'" a''z

* NOTE: For Converters N451033-0202 and -0203, fuses are located on the input/output terminal board.

Top V1EW .SHow,JrJGi l'Jlt~ PLAT~ A~IC.ATlo,,J

(.sco11ui::·'f•I

L.H.l!NO VIEW W•TH £ND ]j~LL R.£MO~E0

+

VtEW;:.

J

Figure 6. Parts List/Locator, F-40 Converters

s 5 5 z z I I

~3 I 100 I 101

102

103 u.17US8~ , .. IOS UJ"7101 •&

IOI,. IIJ47t.81

//0

VlfW LOOKu•u• 11rrJ D1ltf.CT101rrJ 01"" ARROW

.,,....,. 4H.

IJo~<f, .,.. . l!Of.,f. ITS SO<i+ 915A so~,f. S15

WABCO ~,,A./"

1JE6CR.IP'no,J lEV.

Tlt1.N111•.11•L

T41fMtAJlllfL

TQNJ1NAL

Tl1t.M1,JAL

II

9,54 213 POST, FUSC 9 31 HOLDER Fl/SE

FVS~ 8A.1'2.5V, 5ACio II

WIISHC/f. 118M S.Llf'. ,-,. 10

SM-5778, p. 23/24

END BELL RE.TAINING SCRE.wS (G) ( ) ~

8]~ 0

0

B MrG.D1M. 32- SL..oT l 1.-- 23 MTG.

.... ._...______ 9 I _M_A_'l'_. _____ ___,~...i

._,_ ____________ 13 ~ M_A_~-·-----------i

I

II a COI\IOUIT 4 CON~ECTOR

_j

32V-7 2 AMP ;,;. 25011-.150 AMP FUSE

+ + + +

©©@ INPuT 32.V 3SOV

©@

L II MTG i6 SL.OT MTG •

.-..------]: DIM,

FUSE.

.-+---COYER. RE.TAININ4 5CRC:V\IS (<o)

TERMII\JAL­r--;-,1-__C O Ve: R

SCRE'wS (4)

INPUT I OUTPUT TERMINALS

NOTES -* NOTE: For Converters N451033-0202 and -0203,

fuses are located on the input/output terminal board.

ACCESS TO FUSES IS OBTAll'JE.0 8Y REMQvrN(i COVe.R RETAINING SCREW.S A,-JD L.1FT1NG COVER STRAl~HT UP,

ACCE:SS To TE'RMINALS FOFl 11\JPJT A ND OUTPUT INJRINGi IS OBTAINED 8Y UNSC.R.EWIN(i CAPTIVE COVER SCREWS AND REMOVING Te:RMII\IAL Cov~R •

.350 VOL. T TE~MINAI..S ANO • IS AMP FUSE AR.E useo IN DUAL VOLTAGE CONVERTER. ONLY.

Figure 7. Outline Diagram, F-40 Converters SM-5778, p. 25/26