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WizBang Relay Testers

Guest · 2016-09-10T00:38:00Z

Hi Group,I have built and sold around 35 relay testers that test relays found on older equipment. I have another model that tests big relays found on a lot of older independents up to 220 VACI have be out of it for 16 years now so I watch this site with keen interest. Gotta tell you it's a whole new ball game.I hear a lot of chatter regarding relay failures on the newer stuff.I would like to build another tester centered on the newer stuff which would be smaller and lighter.Need some help from you guys, need to know just what relays and what voltages need to be incorporated in my new project.Thanks in advance for your help in keeping a old elevator man out of the Local Beer Joint.Work Safe All

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Technical Questions

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Indirtwetrust

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28/09/2016 10:25 am

I should warn you, these are not very exciting.

https://www.dropbox.com/s/cymx5dvkhtk4sbc/AC%20input%20module.mov?dl=0

https://www.dropbox.com/s/ihnfp53gynxjmi8/DC%20input%20module.mov?dl=0

https://www.dropbox.com/s/w852lww0v138l8j/DC%20Output%20Module.mov?dl=0

https://www.dropbox.com/s/rrm0lqhu5pbg3z4/AC%20Output%20Module.mov?dl=0

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Indirtwetrust

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28/09/2016 10:26 am

And these are wired like this:

?dl=0

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christycollett

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Topic starter 29/09/2016 11:22 pm

Very Exciting, next problem is real estate. Are we going to need 4 PMI sockets? Working on that now.

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christycollett

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Topic starter 29/09/2016 11:35 pm

I'm still excited (at my age it doesn't take much) Save me the trouble. What did you switch on each PMI?

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Indirtwetrust

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30/09/2016 7:09 am

VAC IN on the AC input modules, VDC IN on the DC input modules and VCC on both output modules

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Indirtwetrust

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30/09/2016 7:40 am

What do you think about this for a fully automatic relay tester?

?dl=0

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christycollett

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Topic starter 30/09/2016 8:43 am

Hi Matt,

Been looking for your circuit for years. At one time we had something similar to check all the SY4S relays found in the Montgomery stuff. When a contact failed a crash and burn audio was played. But not nearly as clean as yours. Do we really care which contact is failing or do we care. I like the first part.

If it's bad it's bad.

You have something here brother.

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Indirtwetrust

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30/09/2016 8:55 am

Ya, definitely not going to pinpoint which contact but to find a smoking gun on an intermittent contact failure

here it is working

https://www.dropbox.com/s/tqbllmr6rcac70p/Auto%20Relay%20Test.mov?dl=0

This is with a N/O wire removed and trying to pick and drop as fast as possible to make sure it caught the failed contact

https://www.dropbox.com/s/v8pshgf4v0a68et/Auto%20Relay%20Fail%20Test.mov?dl=0

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christycollett

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Topic starter 01/10/2016 3:33 am

Way Cool,

I see a WizBang Mark XV out there in the near future. Have this PMI thing going right now. How bout in a few days try get this guy in a nice case.

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christycollett

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Topic starter 01/10/2016 4:17 am

Question please,

Re: PMI

Having a little grasping the whole concept here (might be the damaged brain cells from all that beer)

Will the same 120 VAC supply work on both the AC input PMI (pins 1 & 2) and the AC output PMI? Like wise for the 24 VDC supply

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Indirtwetrust

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01/10/2016 7:50 am

Ya, I don't see why not

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slider

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03/10/2016 7:13 am

Probably most know this but on the chance a few don't - the Shrack and the Finder relays are NOT interchangable. The pin size is not only different but shaped differently. A very common source of intermittent problems. Be sure to check socket brand and use only a relay of same brand. And by the way, jobs came out of the factory with relays - sockets not matched.

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christycollett

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Topic starter 04/10/2016 9:47 am

Here is the prelim............
Get your markers out and please let me know what you see needs changing or added.

Thanks,

Jim

https://www.dropbox.com/sh/4s5ob7elx289sly/AAB_8KnxMdRFM7ez_umL5Mw4a?dl=0

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Indirtwetrust

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05/10/2016 10:49 am

That looks right to me! You may consider making room for both a Finder and a Schrack relay base like the TK pic I posted.

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christycollett

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Topic starter 05/10/2016 11:46 pm

Think we are OK, Unless I'm mistaken all three relays have the same contact pile-up only difference in the base is color.

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