Hitachi N342555809, Installation Operation & Maintenance

Page 1: ...SM 4574F 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 PV 250 Track Relay 60 Hz 115 Volt Local STS USA Part No N342555809 N342555909 Installation Operation Maintenance ...

Page 2: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 ...

Page 3: ...a contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible to take into account every eventuality that may arise with technical equipment in service Please consult an STS USA local sales representative in the event of any irregularities with our product STS USA expressly disclaims liability resulting from a...

Page 4: ...005 Incorporated ECO R 1150 Test and maintenance procedures in the manual were updated Reformatted manual 3 April 2005 Corrected resistor values in Figure 3 1 clarified contact block information in Figure 4 1 and clarified contact assignments in Table 3 4 4 March 2019 Hitachi Rail STS Branding Revisions were identified by date only no numbers were assigned to revisions ...

Page 5: ...rvice Requirements 3 1 3 2 Calibration 3 1 3 2 1 Recommended Test Equipment 3 1 3 2 2 Shop Calibration Test Procedure 3 2 3 2 3 In Service and Field Calibration Test Procedure 3 5 3 3 Contact Resistance 3 7 3 4 Shop Maintenance 3 8 3 4 1 Cleaning and Inspection 3 8 3 4 2 Recommended Cleaning Materials 3 8 3 5 Contact Cleaning Procedure 3 9 3 5 1 Contacts that are Severely Burned 3 9 3 5 2 Contacts...

Page 6: ...Base 2 2 Figure 2 2 Receptacle Contact Springs Installed 2 4 Figure 3 1 AC Vane Relay Test Circuit 3 4 Figure 3 2 Adjustment of Heel Spring Clips 3 12 Figure 3 3 Method of Closing in of Lower Heel 3 13 Figure 3 4 Application of Bending Tools 3 13 Figure 3 5 Table Torque Arm 3 16 Figure 3 6 Inspecting Loose Counterweights and Loose Trunnion Screw Locknuts 3 18 Figure 4 1 PV 250 Relay Typical Top As...

Page 7: ... Values at Ideal Phase Relations 3 4 Table 3 3 In Service and Field Calibration Operating Values 3 7 Table 3 4 Contact Assignments 3 7 Table 3 5 Contact Resistance Ohms 3 7 Table 4 1 Parts List for the PV 250 Track Relay 60 Hz 4 1 Table 4 2 Contact Block Arrangement 4 4 Table 4 3 Contact Block Assembly Parts List 4 4 Table 4 4 New Style Mounting Base Parts List 4 5 Table 4 5 Old Style Mounting Bas...

Page 8: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 vi ...

Page 9: ...s e g dropped during shipment or transport This is an indication that the relay may have mechanical damage and may not meet electrical specifications The relay should be opened and visually inspected for damage i e kinked springs Mechanical settings should be checked re calibrated and tested according to specifications by a qualified individual 1 2 Description 1 2 1 General The relay is factory ca...

Page 10: ...this manual 1 3 1 Electrical Electrical specifications for the PV 250 Track Relay are summarized in Table 3 1 Table 3 2 and Table 3 3 1 3 2 Mechanical The mechanical specifications for the relay are shown in Table 1 1 Table 1 1 Mechanical Specifications Dimensions Height 7 1 16 17 93 cm Width 4 15 16 12 54 cm Depth 8 3 8 2 cm Temperature 40 F 40 C to 185 F 85 C Indexing 5509 Weight 8 0 lbs 3 63 kg...

Page 11: ... Figure 4 4 2 3 Relay Indexing Relays are factory equipped 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 is shown in Figure 2 1 The following data defines th...

Page 12: ...ixed to the front of the mounting base This indexing plate should not be removed from the mounting base unless it is damaged or the indexing is to be purposely changed to accommodate a relay of a different part number WARNING Never drill new holes in a base indexing plate that will permit application of relays with different part numbers Never change indexing pins on the back of a relay unless it ...

Page 13: ...acle contact springs for one or two 10 12 wires M451142 2703 or for one or two 18 20 M451142 2701 Make certain the type of solderless receptacle contact springs that accompany the mounting base are the appropriate ones before proceeding with their installation Each solderless receptacle contact spring should be inspected for physical damage before proceeding with installation The following is reco...

Page 14: ... 12 AWG J680181 M451142 2703 J397139 14 16 AWG J680165 Standard M451142 2702 J397188 18 20 AWG J680179 M451142 2701 1 Strip 3 16 in 0 187 in or 0 47 cm of insulation from the end of the wire 2 Place the receptacle contact spring into the jaws of the proper crimping tool When using only one terminal of any wire size use the shortest terminal 3 Partially close the crimping tool jaws against the rece...

Page 15: ...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 side up then plug the relay into the base The relay should be pushed firmly against the mounting base while depressing the latch rod After the relay is completely seated in the base release the latch rod and pull on the handle to ensure that the relay has locked in...

Page 16: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 2 6 ...

Page 17: ...very two 2 years The tests and inspections are to include pick up current drop away current timing of slow operating and timing relays and visual inspection of contacts for damage or misalignment corrosion or other contamination of parts loose parts inside of the cover broken seal and cracked or broken cover Relays not passing the above stated tests and inspections must be replaced and not returne...

Page 18: ...osition 2 Connect the circuit to a 115VAC 60 Hz isolated line 3 Set Variac T1 to its minimum output setting 4 Set switch S1 to the ON position 5 Adjust Variac T2 to obtain 115 VAC 1 across Variac T1 as read by voltmeter V2 This voltage must be maintained throughout this test 6 Slowly adjust Variac T1 to increase its output until all front contacts of the relay being calibrated just close Record th...

Page 19: ...A Current Value __________ 9 Calculate the DA percentage of actual PU DA It must be within the range shown in Table 3 1 DA Step 8 Value Step 6 Value 100 10 When the track energy is reduced to 1 7 volts or 028 amp the vane must have touched the lower roller stop 115 VAC 60 Hz ISOLATED LINE ON OFF S1 T1 A V V 2F 10F L C2 C1 L 1A 10E RELAY UNDER TEST New Style Base Contacts Shown with Parentheses Old...

Page 20: ...ng Values The digital ammeter should be set to display to only three decimal places Values beyond three decimal place accuracy are insignificant to the calibration and should be ignored When the track energy is reduced to 1 7 volts or 028 amp the vane must have touched the lower roller stop The values in Table 3 1 are 13 higher than ideal and apply to test from single phase supply with resistance ...

Page 21: ...to a 115VAC 60 Hz isolated line 3 Set Variac T1 to its minimum output setting 4 Set switch S1 to its ON position 5 Adjust Variac T2 to obtain 115 VAC 1 across Variac T1 as read by voltmeter V2 This voltage must be maintained throughout this test 6 Slowly adjust Variac T1 to increase its output until all front contacts of the relay being calibrated just close Record the value indicated on ammeter A...

Page 22: ... Value __________ 9 Calculate the DA percentage of actual PU DA It must be equal to or greater than 80 of the actual PU value noted in Step 6 DA Step 8 Value Step 6 Value 100 10 When the track energy is reduced to 1 7 volts or 0 028 amp the vane must have touched the lower roller stop ...

Page 23: ...cal L 10E Fronts 7F Front 11B Front 7H Heel 12B Heel L 10F 8F Front 11C Front 8H Heel 12C Heel Control C1 1A Backs 9H Heel 11E Heel 9B Back 12E Back C2 2F 10H Heel 11F Heel 10B Back 12F Back Contacts are standard low voltage silver to silver impregnated carbon fronts and silver to silver backs 3 3 Contact Resistance Resistance of front contacts should be measured with the armature in its full stro...

Page 24: ...amage Proceed with relay contact cleaning using the following recommended cleaning materials 3 4 2 Recommended Cleaning Materials The following tools are recommended for cleaning the relay They are available as a special cleaning kit X451646 0901 Tool STS USA Part Number Burnishing Tool P K Neuses Co No 3 316 J397187 Burnishing Tool P K Neuses Co No N318 Heavy Duty J397187 001 Paper Strip strips c...

Page 25: ... 6 Place the paper strip between the open contacts then close the contacts and withdraw the paper strip 7 Repeat Step 6 several times if necessary 3 5 2 Contacts with Heavy Tarnish Slightly Rough or Pitted Surface 1 Perform the procedure in Section 3 5 1 Steps 2 through 7 3 5 3 Contacts with Surface Film or Oxidation not Pitted 1 Perform the procedure in Section 3 5 1 Steps 6 and 7 3 6 Check Out P...

Page 26: ...ft bracket looking at the relay about 1 4 to the left Do not move the brackets forward or to the rear 2 Disengage the contact operating arms from the clips on the heel contact springs by pulling the arms forward at the lower ends 3 Remove all bushings and pins from the contact operating arms 4 Remove the counterweight nuts from the front end of the vane assembly and loosen the lock nuts from the t...

Page 27: ... one of the trunnion screw lock nuts should be started on the trunnion screws in advance but it may be found necessary to slide the other nut on one end of the vane shaft in order to bring it into position 4 Tighten the trunnion screws carefully so as not to damage the pivots These screws should be adjusted to center the vane in the air gap and to provide 0 010 to 0 016 endplay of the vane shaft W...

Page 28: ...Adjust the heel spring clips with a pair of pliers as shown in Figure 3 2 and Figure 3 3 All bushings should be positioned with the flanges against the heel clips 4 Bend the heel spring supporting members sideways using alignment tool J397164 0020 as shown in Figure 3 4 so that there is clearance of not less than 0 005 nor more than 0 055 to each contact bushing Note Take up the side play of the o...

Page 29: ...ending Tools 3 7 4 Contact Block Replacement and Adjustment 3 7 4 1 Contact Block Replacement Procedure 1 Remove the old block 2 Use a small punch to remove the small dowel pins 3 Attach the new block with the four screws 4 Drill a 42 drill 0 0935 Diameter through the dowel pin holes into the contact block for a total depth of 9 16 1 32 0 ...

Page 30: ...terweight Adjustment Procedure All adjustments of contacts should be made by bending the brass support member with the bending tool applied between the rivets that fasten the contact spring to it Because of the effect of the weight of the contact tips all checks of contact adjustment should be made with the relay in the normal upright position 3 7 5 1 Recommended Tools The recommended tools for sh...

Page 31: ... is held with the base horizontal and the contact springs pointing downward the heel spring will take a free position when not connected to the operating arm without appreciable bias either toward the front or back contacts 3 7 5 3 Final Contact Adjustment Procedure The normal contact adjustment provides 0 031 compression of the front contacts with the vane just touching the upper roller stop 0 02...

Page 32: ...t against the vane shaft 3 Move the small weight that is attached to the adjustable torque arm to give the desired counterweight as specified in Table 3 1 4 Adjust the counterweight nuts on the relay so that the front contacts will just make with the adjustable torque arm in a horizontal position This can be easily determined by tapping the relay case lightly The notches on the arm are spaced to p...

Page 33: ...eight assembly is visible This will reveal one or more counterweights with or without a locknut on the counterweight screw 4 As shown in the figure below check to determine if a The counterweight and locknut are tight b At least two threads are visible on the counterweight screw end c The split screw end is slightly spread apart Tighten any loose counterweights and locknut 5 Conduct a visual inspe...

Page 34: ...n locknut as shown in Figure 3 6 7 Install gaskets and covers and seal with a new wire and lead seal Figure 3 6 Inspecting Loose Counterweights and Loose Trunnion Screw Locknuts 3 7 6 Test for Balanced Magnetic Circuit With the relay standing on its back so that the vane hangs down with front and back contacts open apply normal voltage and frequency to the local winding There should not be any app...

Page 35: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 3 19 ...

Page 36: ......

Page 37: ...2 x 7 16 SS J507295 0119 10 Cover Molded J776304 0001 11 Screw 8 32 x 7 16 J522042 12 Rubber Gasket J047081 13 Screw 8 32 x 1 4 J052639 14 Handle J561111 15 Washer 10 SS J475121 0125 16 Screw 10 32 x 3 8 SS J507296 0129 17 Vent Seal J790257 18 Tag S002036 19 Not Used 20 Wire seal 23 AWG A043013 21 Lead Seal J079351 22 Name Plate M437859 23 Screw 4 40 x 3 16 Pan Hd SS J525024 24 Support Bracket M37...

Page 38: ...43 Pin Bronze M232031 44 Pin M232935 45 Terminal Block PM433457 46 Screw 8 32 x 1 2 SS J500132 0108 47 Roll Pin 3 32D x 1 1 8 J487090 48 Not Used 49 Bag Parts N349711 5509 50 Not Used 51 Contact Block N433482 52 Screw 8 32 x 1 SS J500132 0116 53 Operating Arm N390324 54 Counterweight M451175 0301 M451175 0302 M451175 0305 55 Nut Hex 312 Brass M029956 56 Cover Molded J776598 57 Screw 6 32 x 4 J0524...

Page 39: ...ATE ETC TIED TO RELAY HANDLE FOR SHIPMENT 2 3 27 42 29 4 15 16 7 1 16 45 46 41 8 47 50 52 41 12 51 52 41 11 10 9 41 17 53 37 36 35 38 55 54 23 22 31 44 43 32 12 57 58 28 56 9 11 41 3 8 34 33 18 13 4C5 0123 01 Figure 4 1 PV 250 Relay Typical Top Assembly N342555 809 For specific contact block arrangement please refer to Table 4 2 Table 4 3 and Figure 4 2 ...

Page 40: ...tact Block Contact Section Row 6 5 4 3 2 1 N433482 K K J J Table 4 3 Contact Block Assembly Parts List Item Description STS USA Part No 1 2 Spring Contact N376006 3 Spring Contact N376007 4 Spring Contact N376002 5 6 Finger Contact M375981 7 Spring Contact N376003 7 2 SECTION J 6 3 4 SECTION K 4C5 0126 00 Figure 4 2 Contact Block Assemblies ...

Page 41: ... 1 Molded Base J780054 2 Strike Relay J792848 3 Nut Speed Type J480280 4 Spring Contact M451142 2702 5 Tag Relay ID J075951 6 Screw 1 4 20 x 1 1 4 SS J500136 0120 7 Washer 1 4 Lock SS J475121 0111 8 Washer 1 4 Plate SS J475120 0112 9 Nut 1 4 20 Hex SS J480211 0108 10 Extraction Tool J772383 Contact Receptacle Spring 18 20 Wire M451142 2701 Contact Receptacle Spring 14 16 Wire M451142 2702 Contact ...

Page 42: ...ght 2019 SM 4574F Rev 4 March 2019 4 6 3 5 LOCKING SIDE OF STRIKE 9 8 7 6 5 1 10 2 4 F F F E E E D D D C C C B B B A A A 1 1 2 2 7 7 8 8 9 9 10 10 11 11 12 12 4J1 0029 01 Figure 4 3 New Style Mounting Base Assembly N438689 003 ...

Page 43: ...e 4 5 Old Style Mounting Base Parts List Item Description STS USA Part No 1 Molded Base J776306 2 Coil Clamping Plate J776318 3 Contact Clamping Plate J776308 4 Screw 6 32 x 3 8 J525061 5 Strike M321745 6 Nut M267499 7 Tag J075828 8 Screw 4 x 3 16 J052674 9 Meter Test Plug M322965 10 Extraction Tool J077931 ...

Page 44: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 4 8 4J1 0036 01 4 3 9 10 1 7 7 4 9 5 8 8 2 10 6 Figure 4 4 Old Style Mounting Base Assembly N434647 ...

Page 45: ...ion Link RAIL Team is comprised of a 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 comH ...

Page 46: ...PV 250 Track Relay Copyright 2019 SM 4574F Rev 4 March 2019 5 2 End of Manual ...