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ELECTRIC LEVER LOCK

1. Introduction

Electric Lever Lock is an electromechanical device. It is provided on the mechanical

lever. It is used as an electrical control on a mechanical lever where required. The
lock holds the lever mechanically so that the lever can not be operated when the
conditions for its operation are not safe.

1.1 Type of lever lock

This handbook covers lever lock:

a) 200 mm stroke (SA 22701) for single wire/ ground lever frame.

b) 40 mm stroke (SA 21201/M) for double wire operation.

1.2 Parameters

i) IRS Type Drg. No. SA 22701

(a) Resistance of Coil 4.5 ohm at 20° C
(b) Working Voltage

SR Normal Minimum
1. 110 V AC-50 HZ 100 V AC-50 HZ

2. 10 V DC 7.5 V DC

ii) T-2 Type Drg. No. SA 21201/M

(a) Resistance of Coil 150 ohm

(b) Working Voltage

SR Normal Minimum
1. 10 V DC 7.5 V DC

1.3 Features of Electric Lever Lock

i) Electric lever lock can work on AC supply as well as DC supply, in single wire
lever lock (SA22701).
ii) On DC supply in double wire lever lock (SA 21201/M).

„ It works normally in vertical position.

„ Economiser contact provided in the equipment, helps in power saving.

„ To ensure positive functioning, a force drop arrangement is provided.

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2. Main parts and their function (IRS Type)

Following are the main parts of electric lever lock: (SA 22701)
Adjustable Coupling
(SA21213/M)

Slide (SA22704)

Locking dog (S22734)

Armature lever
(S22743)
Economiser contact arrangement

Electromagnetic Coil
(S22749)

Insulating base with

terminals (SA
21336/M)

Circuit
Controller
(SA 22752)

(SA22708)

Cam
path

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2.1 Electromagnetic Coil (S- 22749)

When all the conditions of operation of lever lock fulfil, the energisation of a
electromagnet coil take place.

Electromagnet Coil

2.2 Armature Lever (S 22743)

Armature is made of magnetic steel laminated sheets which is fixed with armature
lever and resets below the coil, when the current flows in electromagnet coil the
armature is attracted causing Locking dog to release the plunger.

Armature

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2.3 Economiser Contact (SA22752)

It is provided with electric lever lock and circuit controller (200 mm stroke SA
22701) to cut off the power to the lock coil at the end of each stroke. It makes
between “A-E” position of the lever lock and remains disconnected in N and R
position.

Economiser Contact

C
B D
A E
N R

Various operating position of lever

from N (normal) to R (reverse)
position

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2.4 Force drop device

„ This arrangement is provided on the lever lock to ensure safe operation of lever
lock.
„ Sometimes the armature of the lever lock may not release after de-energisation of
electromagnetic coil due to residual magnetism or any other mechanical holding
which may lead to unsafe condition by allowing the lock to release without
proving the required safety conditions.
„ To ensure that the locking dog is positively pushed inside the locking notch before
every unlocking, a mechanical arrangement called “Force drop” is provided.
Q The force drop nib is rivetted on the slide and a bevel shaped extension is
provided with the locking dog.

Force Drop
arrangement

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„ The force drop nib forces the locking dog to drop into the locking notch through its
bevel-shaped extension before pick up.

2.5 Locking Dog (S 22734)

It locks the plunger in required position.

Locking Dog

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2.6 Spiral Spring & Lock proving contacts

2.6.1 Spring ( S 22737)

It is used to obtain forced drop arrangement by pushing locking dog when

electromagnet coil is de-energised.

2.6.2 Lock proving contact

When the locking dog is inside the locking notch of plunger, these contacts make and
when comes out of the locking notch, these contacts break.

Spring

Lock proving contact

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2.7 Slide (S 22704)

Attached with lever tail through adjusting screw, locking notches to lock the plunger
by locking dog in required position.

Q Campath:

It is used to convert linear motion of plunger of lever lock into rotary motion to
operate the circuit controller through teeth and gears with the movement of
controlling stud.

Gear

Teeth
Cam path

Stud

Tappet

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3. Installation

„ Lever lock can be mounted vertically.

„ If the lever lock is to be mounted horizontally, following changes are required:-
• The counter weight is to be removed.
• Coils are to be in parallel.
• Operating voltage should be 110V AC 50HZ.
4. Procedure for marking and cutting of notches on the lock slide of the
lever locks for providing track locking and indication locking:

„ Connect the lock slide to the lever tail through a connecting rod provided with
adjustable slide by means of the adjustable coupling, so that on operation of the
lever to ‘N’ (normal) and ‘R’ (reverse) positions, the respective stoppers should
butt against the body of the lever lock with equal force.

„ Balance the stroke of the lever imparted to the lock ‘R’ (reverse) positions, the
respective stoppers should butt to against the body of the lever with the equal
force. This ensures that full 200mm (8") stroke is imparted to the lock slide.

„ Keeping the lever in ‘N’ position, mark the normal position of the lock slide
coinciding with the inner edge of the slot on the body of the lever lock for
insertion of locking dog.

„ Keeping the lever in ‘R’ position, mark the reverse position of the lock slide
coinciding with the inner edge of the slot on the body of the lever lock for
insertion of locking dog.

„ Take out the lock slide from the lever lock and ensure that, the distance between
the two markings N and R is 200mm i.e. the travel of the lock slide plus width of
the locking dog.

„ Cut the notches as per dimensions. A typical sketch is shown.

N A B D E R
74 mm
49 mm 49 mm
26 mm 26 mm 5 22
62
m m m
m m m

12 mm
200 mm

224 mm

„ Now connect the lever lock in the concerned lever.

„ Operate the lever and ensure that notches are in proper places.

„ Tight the connections of lever lock.

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„ Drop the concerned track circuit and try to operate the lever lock, it should not be
operated. Now pickup the track circuit and see that lever lock is operating
properly.

„ Hold the armature loosely by hand and operate the lever from locked position, a
downwards force is experienced on hand which indicates that the force drop
device is functioning properly as given in figure below.

„ Operate the lever slowly and see that after each stroke power is cut off to the lock
coil. It makes during “A-E” positions of the lever and remains disconnected in ‘N’
and ‘R’ positions.

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5. Main Parts and their functions

T-2 Type (SA 21201/M).

Followings are the main parts of 40mm stork (SA 21201/M) T-2 Type lever
lock.

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5.1 Lock Cam. (S 21222/M)

It locks the lever in required position. Locking segments for various notches
are available separately and may be used as per requirement.

5.2 Lock (Complete) SA- 21247/M

It locks the lever in required position. A bevel- shaped extension is provided

with the locking dog and used for force drop the locking dog in to the locking
notch.

Adjustable nut

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„ When electromagnetic coil energised, bevel shaped extension houses in

side the notch given in lock-cam segment and lever becomes free for
movement.
„ Taper portion of notch pushed the bevel shaped extension to pushed
locking dog in side the locking notch before every unlocking.

5.3 Rack and pinion.

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5.3.1 Rack. (S 21207/M)

„ Rack is attached with adjustable coupling.

„ Rack moves vertically up and down position.

5.3.2 Pinion. (S 21220/M)

„ It is used to convert linear motion of rack of lever

lock in to rotary motion to operate the circuit
controller.

5.3.3 Movement of rack.

„ When clutch press in normal position, rack moves 20mm in up direction.

„ During operation of lever from “N” to “R” position no movement takes
place by the rack.
„ When lever fully operated in “R” position and clutch releases rack moves
again 20mm in up direction.
„ Total movement of rack is 40 mm in up direction when lever operated
from normal to reverse and 40 mm in down direction when lever operated
from reverse to normal position.
6. Maintenance

„ Ensure that cable conductors are properly laced. Loose wire insulation may get
cut and create unsafe condition.

„ Check that all moving parts are clean, oiled and working freely.

„ Check the economiser contacts and lock proving contacts for their proper function
and adjust them, if required.

„ Measure the operating voltage and current at lock coil terminals, if not within
permissible limit adjust them.

„ Check the faces of the locking notches on the lock slide, they should not be round
otherwise lock armature may slip.

„ Check and ensure that all terminals, screws and nuts are properly tightened.

„ Ensure that lock armature works freely.

„ Ensure the proper functioning of force drop arrangement.

„ Ensure that split pins are in position and properly split.

„ Ensure that the lever can not be operated when the required safety conditions for
its operation are not fulfilled.

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„ Ensure that the staff operating the levers are familiar with the operation of the
levers fitted with the lever locks. Such levers should be operated gently i.e.
without jerk after the lever getting un-locked electrically.

7. Do’s and Don’ts

7.1 Do’s

„ Check the operating voltage and current.

„ Check that all moving parts are free.
„ Check that cable conductors are laced properly.
„ Wires should not be infringe with moving parts or no chance of crushing of their
insulation by covers.
„ Check and ensure that split pins are in proper shape.

7.2 Don’ts

„ Loop up the economiser contact.

„ Forget to ensure the firmness of the force drop stud.
„ Leave the split pin un-split.
„ Fail to check the plunger stop pin.
„ Forget to check the economiser contacts function.
„ Put up or try to adjust the parts during lever movement.
„ Replace any parts without sanction/ permission on dis-connection memo.
„ Forget to replace the plunger if its notches are worn-out i.e. not serving the proper
function.

„„„„„

Maintenance Handbook on August 2000

Electric Lever Lock