Hitachi 152SO, Installation & Operation Manual

Page 1: ...SM 5924 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 PN 152SO Switch Overload Relay STS USA Part No N322522 001 N322522 802 Installation Operation ...

Page 2: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5924 Rev 3 March 2019 ...

Page 3: ... the prior written consent of STS USA Important Notice STS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties W...

Page 4: ... Revision History Rev Date Nature of Revision November 1980 Original Issue March 2000 Revision 2 November 2003 Revised to indicate that part number N322522 001 3 March 2019 Hitachi Rail STS Branding Revisions were identified by date only no numbers were assigned to revisions ...

Page 5: ...rformance Test 3 1 3 2 1 Cleaning 3 1 3 2 2 Service Requirements 3 1 4 SHOP MAINTENANCE 4 1 4 1 Adjustment and Calibration 4 1 4 1 1 Operating Relay 4 1 4 1 2 Stick Relay 4 1 4 1 3 Preliminary Calibration 4 2 4 1 4 Internal Wiring 4 3 4 1 5 Final Calibration 4 3 4 1 6 Service Recommendations 4 5 5 TECHNICAL SUPPORT 5 1 6 PARTS LIST 6 1 6 1 PN 152SO Relay Complete 6 1 6 2 PN 152SO PARTS LIST Unit A...

Page 6: ...ble 4 1 Electrical Adjustments and Calibration 4 12 Table 5 1 Parts List References for PC 250B Code Following Vital Relay 5 1 Table 5 2 PC 250B Code Following Vital Relay Main Assembly Parts List see Figure 5 1 5 2 Table 5 3 Parts List for Operating Unit Item 11 Used on PC 250B Code Following Vital Relay see Figure 5 2 5 5 Table 5 4 Parts List for Contact Assembly Used on PC 250B Code Following V...

Page 7: ...pening the motor control circuit The thermal resistor has a high temperature coefficient of resistance so that with excessive motor current its resistance will increase giving a longer cut out time for a lower current and a shorter cut out time for a higher excessive motor current 1 2 Shock Indicators WARNING Any relay showing shock indicator activation should be sent to the shop for inspection be...

Page 8: ...o 185 F 85 C Indexing 2201 2202 Weight 4 0 Lbs 1 814 kg Mounting Base N398314 Old Style N451376 0302 New Style 9 oz Mounting Base Dimensions Height 7 15 16 20 1 cm Width 2 7 16 6 19 cm Depth 2 7 16 6 19 cm Old style Base 1 25 32 4 5 cm New style Base 1 4 Electrical Specifications The electrical specifications shown in Table 1 2 are common to all PN 152SO relays covered in this manual Table 1 2 Ele...

Page 9: ...uipped with indexing pins to prevent insertion of an incorrect relay into a mounting base Each relay is accompanied by an indexing plate that is applied to the mounting base at the time of initial installation A typical plug in relay with indexing pins and base with corresponding indexing plate are shown in Figure 2 1 The following data defines the indexing established for relays covered by this m...

Page 10: ...different part numbers Never change indexing pins on the back of a relay unless it is being converted to a new part number otherwise a hazard will be created that may compromise safety circuit functions 2 4 Receptacle Contact Springs 2 4 1 Old Style Base Only N398314 The N398314 mounting base normally will be equipped with the required quantity of J680165 solderless receptacle contact springs and ...

Page 11: ...lled 2 4 3 Installing Wires in Receptacle Contact Springs Use the following procedure to ensure a good electrical and mechanical connection between the conductor wire and the receptacle contact spring Table 2 1 identifies the correct crimping tool to be used when installing wires in receptacle contact spring Table 2 1 Crimping Tools Crimping Tool Wire Size Old style Receptacle Contact Spring Impro...

Page 12: ...re to the longest terminal This ensures that a second lead may be attached to the receptacle contact spring at a later time 5 Remove the crimped receptacle contact spring from the tool and inspect the connection Make certain that the wire is flush with the crimped barrel and that there are no loose strands of wire 2 5 Relay Insertion Orient the relay to the mounting base with the name plate right ...

Page 13: ...irt grease etc 3 2 2 Service Requirements 3 2 2 1 General All PN 152SO relays must be inspected and tested at least every four 4 years The tests see Table 4 2 and inspections are to include pick up time at given current visual inspection of contacts for damage misalignment corrosion or other contamination of parts loose parts inside of the cover a broken seal and a cracked or broken cover Relays n...

Page 14: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 3 2 ...

Page 15: ...e at the free end of the armature insulation should be 0 080 0 002 inch c The continuity contact should be adjusted as follows 1 The front contact lower spring should be adjusted to exert a pressure of from 10 to 15 grams on the armature in the deenergized position 2 The opening between the front contact and the heel upper spring should be from 0 020 to 0 025 inch with the armature in the deenergi...

Page 16: ... 1 Circuit for Preliminary Calibration The load springs and front contact heel of the Operating relay and the front contact spring of the Stick relay may be given a slight readjustment of their pressures if necessary to meet the specified pick up values a Drop Away Each Style L relay shall be given a charge of four times the pick up value and the current then gradually reduced until the armature d...

Page 17: ... complete overload relay including the thermal resistor connected across the operating relay coil Figure 4 2 Wiring Facing the Front of the Relay Final calibration should be made with the relay cover applied to give normal functioning of the thermal resistor After a given test the thermal resistor must be permitted to cool before the test is repeated Test the relay in a circuit in accordance with ...

Page 18: ...r Figure 4 3 Final Calibration When the operating relay picks up it energizes the stick relay which in turn releases the heavy duty relay When the heavy duty relay drops out it interrupts the overload current circuit to the operate relay Heavy duty release interrupts the overload current to the operate relay which drops out Successive tests of operating time must be made Allow sufficient time for ...

Page 19: ...ould another operation be tried with less than six seconds cooling time or the relay may not have sufficient motor surge current protection When adjusting or working on a switch machine apply a jumper between terminals HV and HV to shunt out the thermal resistor Of course the jumper must be removed for normal circuit functioning Switch machine clutch slippage should be maintained at approximately ...

Page 20: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 4 6 ...

Page 21: ...PPORT The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam hitachirail com ...

Page 22: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 5 2 ...

Page 23: ... Nut 6 32 Elastic Stop J048142 12 SCR SST 6 32 x Fh J507298 0120 13 Contact Block N398287 14 Screw 6 32 x Fl Hd J052121 16 Relay Support M398308 17 Relay L 10 Unit B N398335 18 OR 10 Relay Unit A N398329 19 Bushing M398261 20 SCR 10 32 x Rd Hd J525040 21 Handle Pull Aluminum J561111 22 Wshr SST 10 Shak Pf J475121 0125 23 SCR SST 10 32 x 3 8 Ph J507296 0129 24 Distortion Bracket M303869 25 Screw 10...

Page 24: ...39 Tag Calibration S000997 40 Screw 10 32 x 5 16 Fil Hd J522015 41 Bag of Parts N330681 2202 43 Tag Instruction S000661 44 Wshr SST 170 Id Flt J475121 0127 45 Wshr SST Lock No 10 J475121 0109 205 W 20 PVC Wht M258 30 A0455505 0008 225 W 20 PVC Slt M258 30 A0455505 0007 230 W 20 PVC Brn M258 30 A0455505 0003 235 W 20 PVC Blk M258 30 A0455505 0001 899 Shock Indicator J680167 0012 Where mounted ...

Page 25: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 3 Figure 6 1 PN 152SO Internal Parts Location Sheet 1 of 3 Dwg D66000 33 ...

Page 26: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 4 Figure 6 1 PN 152SO Internal Parts Location Sheet 2 of 3 ...

Page 27: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 5 Figure 6 1 PN 152SO Internal Parts Location Sheet 3 of 3 6 2 PN 152SO PARTS LIST Unit A ...

Page 28: ...mature Stop M152756 25 Screw 6 40 x 3 16 Fil Hd J052247 30 Steel Washers M184967 35 Copper Washers M158914 40 Core Component N255526 42 Pin 063 Drill Rd M141720 45 Wshr Spring Ph Bz J475181 50 Screw M186081 55 Lock Washer M243846 60 Contact Section N398328 65 Contact Section 1 F Contact N371034 0001 When reordering contact section be sure to include the 0001 suffix This suffix indicates certain pr...

Page 29: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 7 Figure 6 2 PN 152SO Part Details Unit A ...

Page 30: ... 063 Drill Rd M141720 15 Coil 750 Ohm N163282 20 Wshr Spring Ph Bz J475181 25 Lock Washer M243846 30 Screw M186081 35 Plate Base M152751 40 Screw 6 40 x Fl Hd J052060 45 Screw 6 40 x 3 16 Fil Hd J052247 50 Armature Steel N291232 55 Armature Stop M152756 60 Cont Section Comp N190227 0001 When reordering contact section be sure to include the 0001 suffix This suffix indicates certain processes perfo...

Page 31: ... Steel J522090 20 Strike M321745 25 Nut 312 Brass Hex M267499 30 Sheet Instr Form 7 S000007 40 Tag Vinylite J075828 45 Screw 4 x 3 16 Rd Hd J052674 50 Bag Plastic J078399 65 Spr Contact Receptacle Solderless 10 to 12 wire 14 to 16 wire 18 to 20 wire J680181 J680165 J680179 70 Screw 20 x 1 1 4 Rd J052667 75 Washer Steel Lock Med J047775 80 Washer Steel Plate J047501 85 Nut 20 Unc 2B Hvy J048002 90 ...

Page 32: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 10 Figure 6 4 PN 152SO Base and Test Plugs ...

Page 33: ...51 11 Sheet Instr Form 8 S000008 12 Bag Plastic J078399 15 Screw 4 x 3 16 Rd Hd J052674 16 Extraction Tool Used for opening any coil or contact circuit and for removing receptacle springs J772383 NOTE A When Mounting Base complete is ordered a plastic bag of parts is included in the inner carton with the mounting base and instruction prints Bag Contains Tags Item 10 Screws Item 6 Items 6 7 8 and 9...

Page 34: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 12 Figure 6 5 New Mounting Base for PN 152SO Relays ...

Page 35: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 13 ...

Page 36: ...PN 152SO Switch Overload Relay Copyright 2019 SM 5929 Rev 23 March 2019 6 14 End of Manual ...