INSTRUCTION

PAMJ'B,LBT HUMBER U--5083

UIIIOII swnc• a ua11u •.... SWISSY.lllrB, PL
DIVISIOH OF WESTIHGHOUSE AIB BBAXE COHPAHY

SERVICE SPBCIFICATIOJIS l'OR DODE RECEIVER

'
·.! Intermittent Inductive Autollatic Train Stop -
Inspection, Teat and Repair or Engine Receivers
*************************************************
Catalog Platea K2o8,, 11208A, 112088., 112o8c
*************************************************

Winding
The winding or the receiver consists or two coils., a
priaarJ' coil, Pc. 131JS11-6-Bl2571-Sh. Ji. and a secondary coil.,
Pc. 134547-Bl2571-Sh. 5.
The coils are machine woW1d, and the coil 1181ldrel is to
be covered with one piece or·o.016" - 0.019" D1sr1co 5-11/16"
x 16" berore winding.
The coils are to be started at the end or the 1118.lldrel
away rrom the he~d ot the winding 11&ch1ne., and wound 1n the
direction indicated on the coil drawings Bl2571 - Sha. 4 & 5.
The coils to be wound with one continuous length or wire., no
Joints being permissible.
Pr.imaljZ: The erillary coil shall be wound with 2050
turns of #1 (A.W.G.J·O.E. Co's. l'oraex Class "HF" copper
wire., with a tap at the 1835th turn.
The resistance or the primary coil should be 13.35 ohms.,
plus or minus 5~, and the resistance between the tap and the
end ot the coil should be 1.65 ohms., plus or lllinus 5~, at 75°P.
After.the coil has been wound, it should be taped with
one layer 0.007 11 x·3/4" cotton tape, overlapping one halr.
The leads shall be nwnbered 1-2-3. The inside lead to
be #1, the tap lead #2, and the outside lead #3. The identifi-
cation ot leads must be ot such character that handling ot the·
coils will not cause it to be lost.

Revised: Sept. 4, 1953

u. s. & s. -2- U-5083

.
Secon~: 'l'he secondary coi.l is to be wound with 2700
turns of #20A.W.G.) G.E. Co•s. Formex, Class ·"HF" copper wire.
The inside lead should be numbered #1; and the outside
lead /12.
The resistance should be 27 .40 ohms plus or minus 5'1,,
at 75°F.
At"ter the coil has been wound, it should be taped with
one layer or 0.007 11 x 3/4" cotton tape, overlapping one halt" •
. Testing Coils For Short Circuits-
Number or Turns
The'coils should be tested ror number or turns and short
circuited turns. Any standard method or testing coils ror
number or turns and short circuits will be satisi"actory, but
in checking ror short circuited turns the sensitivity or the
method must be such as to detect one or more short circuited
turns.
Ii" rurther ini"ormation on test methods is desired, the
manufacturer will i"urnish it on request.
Impregnation
All coils should be impregnated in a vacuum tank with a
non-oil proof asphaltum compound. 011 or any other solvent ot
the compound should not be allowed to get on the coil. Ir
facilities are available for doing this work, further 1ni"orma-
tion pertaining to the impregnating process will be furnished
by the manufacturer on request.
After the coils have been impregnated and drained, one
layer of 0.007" x 3/4 11 cotton tape overlapping one half should
be applied.
Applying External Leads
The leads or the coils should be applied as indicated
on the drawing Bl2571-Sh. 4 - Sh. 5 revised 5/9/31, care be-
ing .taken to conform to the dimensions and instructions given
as closely as practicable. The leads are 14-1/2 11 of #14 B & S
gauge extra flexible 41 strands of #30 (0.010") tinned
copper wire with 3/64" wall :plain no braid rubber or equivalent.
·care should be taken to use a minimum amount ot in-
sulating material around the coil leads, and to keep the
raised portions of the coil where the leads lie as low as
possible.
u. s.· &: s. -3- U-5083

Rubber Covering
A good grade rubber tape, (2" wide and 1/32" thick), is
to be used for covering the coils. "USCOI' Rubber Splicing
Compound Tape of the U. s. Rubber Company, or its equivalent,
has been found satisfactory for this purpose.
The coil ls to be covered with two layers of rubber tape
overlapping one half. These layers are to be put on in the
regular way. Then apply one layer with at least 1/2 laps
around the outer periphery of the coil so as to give extra
covering where the laps of the first two layers are the least.
The tape shall be carefully worked around the leads using
short pieces of tape and rubber cement to seal the Joints.
Each layer should be allowed to dry before another layer is
put on. Tape shall be tightly stretched as it is applied so
that the' joints will be well sealed. A steel or wood roller
should be used to seal the laps thoroughly, going over each
layer of the entire coil. The tape must be kept clean as it
is applied. The joint around the leads should be at least
1-1/2" in length. Great care should be taken that no strings,
cotton tape, or other material extend through the rubber tape
which might conduct water to the inside of the coil.
After the rubber tape has been applied, a single layer,
one halr:: lap, of 3/4" good quality friction tape shall be put
on.
Vulcanizing Coil
A1'ter the tape ls applied, the coil shall then be
vulcanized in an oven at 180°F. for 30 minutes. The oven should
be provided with a regulator to keep the temperature within
these limits.
Varnishing Coils
After the coils have been vulcanized, they shall be
given one dip coat of air drying varnish. Sterling H.B. Core
Plate Varnish - Sterling Varnish Co., - is satisfactory for
this purpose.
Waterproofing Test
All coils are to be placed in water in a metal container
for not less than six hours.
The depth of the water should be such that the coll leads
will be covered well above the point where the rubber tape makes
a Joint with the external leads. They should read infinity on
a megger when tested between leads and metal container.
 u. s. & s. -4- U-5083

Do not allow ends of lends to enter the water.

The coils should be dried thoroughly before assembling.
The drying may be hastened by placing the coils in an oven
at not over 125° ~- for two or three hours.
Laminated Core and Core Foot.
. .
The laminated core ls to-be assembled as indicated.
SIDE PLATES 34 LAMINATIONS
/#138515 RIVET #134570

II II iI 2 LAMINATIONS
#134588

'· Fig. 1
If it becomes necessary to take the core laminations
apart to clean or remove rust, they should be painted with #90
Core Plate Va:r-nish, Sterling Varnish Company, before assembl-
ing. It is important that all burrs and sharp.edges be re-
moved before assembling. The assembled core should be impreg-
nated in a non-oil proof asphaltum compound. Impregnating is
superior to painting to prevent rusting of the laminations, but
if facilities for impregnating are not available, it is suggested.
that the assembled core be given two coats of Pratt & Lambert's
#1 turpentine black asphaltum.

------~==
~--qy--~~
--------
------------
.::.=-- ---=-----~~=-=--=-:::
- - - - 5 OF Pe.#134571
- - - - - 5 OF PC.#134572
. - - - 5 OF PC.#134573
R.H. 'CORE FOOT
. - - - 5 OF PC# 1345 74
5 OF PC.#13457.S
14 OF PC.#134578
Fig. 2
The Core foot is to be assembled as indicated above.
The L, H. Core Foot is identical except assembly is reverse.d.
If it becomes necessary to take the Core Foot laminations
apart to clean, remove rust, or straighten the laminations,
u. s. & s. -5- u-5083-·

the treatment of individual laminations, and assembly, should

be as discussed above for the core laminations and assembly.
Assembly of Coils on·Core
Place -0oils_on core as shown in Fig. 3 an9 make a polarity
test before wedging, to determine that the coils have been wound
in the proper direction and the leads brought out at the proper
end_ of the coil and as specified on the· drawing~
The polarity test should be made whenever a coil is
removed from the core, ·recovered, or new leads applied.
Refer to Fig. 3 and mak~ polarity test.as follows:
P\ace the receiver core in a North-South position with
the primary coil toward the North.· · Piace a compass· a few inches.
to the North-East of the primary. end (at the side). Note the
position of the compass needle. Connect a dry cell to the leads
of the primary coil, making #1, (NA) lead positive. Note again
the position of the compass needle. Connect the dry cell to the
secondary coil, making the #1 lead positive, and note the position
of the compass needle. The needle should point in the same
direction in all three cases.

2 1 3 2 1 -......_.,.,,.

Q Q NSQ Q A O 0 0
II
NA
------tSECONDARY PRIMARY . z-
WWW .,
I I
I
I
t
I
L--- _ _ _ _ _ _ __,
8 COMPASS

ONE DRY CELL

Fig. 3
u. s. & s. -6""'. U-5083

Wedging Co1ls on Core

r .
After the polarity test has proved the coils are correct·
they should be wedged on the core as shown in Fig .. 4.
PLACE LEADS OF
COIL ON LINE WITH
FLAT PART OF C~RE.
SPLICE
APPROXIMATELY THE RAISED PART
IN THIS OF LEADS SHOULD
LOCATION JUST TOUCH FLAT
PART OF UPPER ·
COVER.
FILLER PIECES;
PRIMARY COIL - ·
PC. 1389§0 DRIVEN WEDGES:
SECONDARY COIL- PRIMARY COIL-
PC. 133542 PC. 138949
4-EACH COIL SECONDARY COIL-
-~.w.~-- PC. 313 611 .
4-EACH COIL

Fig. 4
Use .an upper cover to position the coils correctly in
relation to the housing bolt holes through the core. At the
same time rotate the coils around the core to position the
lead humps properly. When positioning the lead humps in the·
upper cover, {if the coil is loose on the core), it should be
remembered that the wedging will centralize the coil around
the core and will bring the lead hump higher in relation to
the cover tha.n the unwedged coil resting on the core. Crayon
marks on the face of the coil for reference points will help
to maintain proper positioning during the wedging. It will
help if the ends of the core are placed on rigid supports or
suitable height above the table to keep the coils above the
table.
1. Liberally apply Minnesota Mining & Mfg. Co. Cement
EC-524 on all four faces of the core on the entire area under
the coils.
2. The filler pieces, (#138950 for primary coil and
#133542 for secondary coil), are to be painted liberally on ;
both sides with 3M Cement EC-524 and inserted next to the coll
as shown in Fig. 4. Leave about 2" extending out from the end
or the coils, on all four sides of the core, until the driven
wedges are inserted.
3. Driven wedge Pc. 138949 is 6" long and used for the
primary coil. Driven wedge Pc. 313611 is 5-7/16" long and used
for the secondary coil. All driven wedges are to be painted liberally
u. s. & s. -1- U-5083

on both sides, f'or a length of' 5" f'rom the entering end. The
thin end is then inserted between the :filler piece and core f'ace
on all f'our sides o:f the core f'or both primary and secondary_co1ls.
_ Drive wedges in about 2" and then tap all f'iller pieces 1n-
f'lush with the end of' the coil on both primary and secondary coils.
Care must be taken to be sure that the coils do not shif't
from the established correct position during the wedging operation!
Drive the wedges in uni:formly from both ends with the aid
of' a suitable d~iving block. All wedges should be driven in until
they "batter" unif'ormly on the end. Then cut of':f only the battered
portion and drive un_til it again ,,batters" uniformly O!l the end.,
whe~ it can be assumed the wedging is adequate. Cut of'f' the remain-
ing portion of' the.wedge tlush with the end of' the coil.
If' it is f'ound that the wedges drive too easily, indicating
a sli§htly larger inside diameter of' coil, a flat bakelized canvas
"shim 3/64" thick, (Pc. 307749), should be painted with 3M cement
and inserted between the core and driven w~dge on one or more
faces of' the core. Then drive in the wedge and shim until they
''batter, .. as discussed above. The shim should be at least as f'ar
in the coil as the driven wedge.
Splice between Primary and Secondary Coils.
Care shall be taken to make the splice, between #2 primary
lead and #1 secondary lead, waterproof and to provide some slack.
See Fig. 4.
The wires should be well twisted to make a straight splice
and then soldered. Af'ter soldering the Joint should be gone over
with a pair or pliers to remove any loose wires or sharp points
or solder which might puncture the rubber.
The splice should be covered with a good splicing compound.
Just before applying the tape, clean the rubber on the two leads by
scraping lightly with a knife. Draw the rubber tape tight as it
is applied and cover the rubber for -,about an inch on each side
of the joint. Hold in the hand for a minute or so until it is
well sealed. Then paint with a good grade of' insulating paint
and when dry cover with f'riction tape and paint again with insulating
paint.
The remaining leads should then be connected to the corres-
ponding posts on the terminal board, using great care that the
leads are not crossed. Terminal #179677-Sh. 121-8244 should be
applied-by clamping the insulation and soldering the conductor
in the terminal, Pc. #179677.
u. s. & s. -8- U-5083

After the term:lnals are assembled on the terminal board the

leads should be suitably positioned and then apply two turns of'
friction tape, (suitably located)., around the coil to anchor each
lead securely. It is recommended that no tape be applied around
the crack between ends of' the coil as :it mi.ght conf'ine moisture
and cause a ground conditipn.
Applying Pole Pieces and Brackets
1. The side plates., Pc. #138515., of the core, should be
thoroughly cleaned of all paint and grease f'rom the coils to the
ends of' the core. An emery sanding disk would be preferable to
use to clean these surf'aces effectively. Also clean excess paint
from the corners f'ormed by the side plates and laminations.
2. All~paint and grease should be removed from the assembly
side plates Pc. #134330 and Pc. #13451Ji.. This may be done by
soaking the plates in a lye vat. See Fig. 6.
3. Remove all paint and grease from the finished surface for
the core assembly on the back of' the brackets., and the lower face
of the extension lug on the back of' the brackets.
4. Remove all paint and grease .from the side plates of the
core feet. Pc. #134565 and Pc. #134566. See Fig. 2.
5. The thickness of the core should be 2" minimum., and the
core :foot 2 11 maximum. If the core is under 2" it should be built
up in assembly with sufficient steel shims per Fig. 5. The core,
core feet and brackets are to be assembled as shown in Fig. 6 •
il
.. HOLE
32

.042 11 STEEL SHIM T 111

1-
2

J_
3 ..
3-
4

Fig. 5
u. s. le s. -9.,;. U-5083

3 PLATE$ - - - . . . 1 ·
1/8.THICK
PC.134330

CORE
CORE FOOT

:" .. •
\..>----- 1/4 PLATE
PC.134514

Fig. 6
It it is necessary to add shims to make the 2 11 thicJmess
ot
the core the shims should be inserted at the back of the core, be-
tween the core and the three 1/8" thick plates Pc. #134330.
First tighten the bolts through the core toot and then
tighten the bolt through the core. Do not tighten the bolt
through the extension lug. With only the core toot and core
assembly bolts tight check that there is a gap ot at least 1/32"
between the end ot the extension lug on11 the back of the bracket
and the nearest plate of the three 1/8 thick plates at the back
ot the core. It this gap does not exist the extension lug should
be trimmed oft to provide such gap with only core foot and core
assembly bolts tight. See Fig. 6. When this condition has been
satisfied tighten the bolts through the extension lugs. Check
that all assembly bolts are tight, and that lock washers and
cotter pins are on each bolt.
6. Apply plug connector and connect the wires to the proper
terminals on the receiver terminal board.
1. After the receiver has been completely assembled, all ex-
posed surfaces should be given a protective coat of black paint.
Electrical Tests
1. Short Circuited Turn Test. After ~he receiver has been
assembled a test should be made for short circuited turns. The
~esonance Test Set tor relays and receivers is Pc. #243923-D2443-
Sh. 14. If test set is not available a Schematic Wiring Diagram
and test values tor relay and receiver is shown on page 11. In
u. s .• s. -10-

making this test, the reee1.ver should be placed on a wooden support·,

..
away i'"rom close proximity of' 1.ron or steel structures or other
rece1.vers., as 1.t w1.ll &rf'ect· ·the results of' the test. It is very
important .that the condensers used are of' the exact values apec1.:fied
and should be checked f'requently to insure that the capacity does
not change. In making th1.s resonance test on the primary., the
secondaey., or the relay, tune f'or maximum current in each case
and read the current and tuning capac1.ty. This test will not only
show any short circuit in the receiver coils., or relay., but also
•. .
a low leakage resistance across the secondary terminals, which might
divert the induced current, that drops the relay.
Ground Test. The completed assembly should be g1.ven a ground
test between the cover and any one of' the three terminals. The
megger.should read inf'inity.
. Operating Test. Af'ter the above tests have been made the
receiver should be plugged in the standard shop test equipment.
Note that tbe pri.mary and secondary circuit voltage and current
conforms to the limits :for a standard equipment. This test will
also check that the wires between the receiver and plUg connector
have been properly connected and tagged.
Resistance Check--Assembled Receiver
It may be desired, at times, to know the resistance of' the
primary, secondary, or primary tap of' the coils of' a receiver in
service.
This may be. determined by using the f'ollow.bg method:
NS A NA

SECONDARY; PRIMARY

F • Resistance measured between NS-NA

D = Total resistance of' secondary and tap of primary NS-A
E = Total resistance of primary A-NA
X = Resistance of primary tap
D-X+E-X:F
2X • D + E - F
X • D+ E - F X should be 1.65 ohms plus or minus 5~
2

. It is important that these resistance values be accurately

measured, and it is recommended that a Wheatstone bridge be used
tor this purpose. ·
 U.S.&S. -11-:_ U-5083

MILLIAMUETER
W.ESTON MODEL 155
75 MA RANGE -

CONNECT THESE
TERMINALS
4
HOVOLTS TO RELAY OR RECEIVER
· 80CYCLES -TERMlflfALS

TRANSFORMER ADJUSTABLE
CONDENSER
,. ' 4.0 UFO.TOTAL

TRANSFORMER:
PC. NO. f37327-C8805-SH.8 RELAY TOP PLATE
CONDENSERS:
1.0 MFD. PC. NO. 244185-812549-SH.21
0.5 MF'O. PC. NO.219113- 812549-SH.21
0.2 MFD. PC. N0.19915_5-812549-SH.28
2.0 MFO. PC. N0.199468-61.2549-SH.21

TEST VALUES:
WITH 12 VOLTS APPLIED AT TERMINALS
RE LAY S ANO NS 3.t Mf'D. MAXIMOM 41 MA. MINIMUM
RECEIVER A AND NS 1.9 MFO. MAXIMUM 23 MA. MINIMUM
RECEIVER A ANO NA 3.0 MF"O; -MAXIMUM 33.5 MA. MINIMUM

SCHEMATIC WIRING DIAGRAM- RESONANCE TEST SET

INTERMITTENT INDUCTIVE TRAIN STOP

RESONANC.£ TES·T SET FOR RELAYS ANO

RECEIVERS PC.N0.243923-D2 443-SHEET 14
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