Hitachi 152SO Guide

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

PN-152SO Switch Overload Relay
Copyright 2019 SM 5924 Rev. 3, March 2019

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 i
Proprietary Notice
This document and its contents are the property of Hitachi Rail
STS USA, Inc. (formerly known as Union Switch & Signal Inc.,
and hereinafter referred to as "STS USA"). This document is
furnished to you on the following conditions: 1.) That no
proprietary or intellectual property right or interest of STS USA
is given or waived in supplying this document and its contents
to you; and, 2.) That this document and its contents are not to
be used or treated in any manner inconsistent with the rights of
STS USA, or to its detriment, and are not to be copied,
reproduced, disclosed or transferred to others, or improperly
disposed of without 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.
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 any improper handling or use of our
equipment, even if these instructions contain no specific indication in this respect. We
strongly recommend that only approved STS USA spare parts are used as
replacements.

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 ii
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.

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 iii
Table of Contents
1. INTRODUCTION ...............................................................................................................................1-1
1.1. Introduction ............................................................................................................................... 1-1
1.2. Shock Indicators ....................................................................................................................... 1-1
1.3. Mechanical Specifications ........................................................................................................ 1-2
1.4. Electrical Specifications ............................................................................................................ 1-2
2. INSTALLATION.................................................................................................................................2-1
2.1. General ..................................................................................................................................... 2-1
2.2. Mounting Base.......................................................................................................................... 2-1
2.3. Relay Indexing .......................................................................................................................... 2-1
2.4. Receptacle Contact Springs ..................................................................................................... 2-2
2.4.1. Old-Style Base Only (N398314) ...................................................................................2-2
2.4.2. Improved One-Piece Base Only (N451376-0302)........................................................2-2
2.4.3. Installing Wires in Receptacle Contact Springs............................................................2-3
2.5. Relay Insertion.......................................................................................................................... 2-4
3. FIELD MAINTENANCE .....................................................................................................................3-1
3.1. Introduction ............................................................................................................................... 3-1
3.2. Periodic Performance 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”) ........................................................................................... 6-5
6.3. PN-152SO Parts List (Unit “B”)................................................................................................. 6-8
6.4. PN-152SO Base and Test Plugs Parts List .............................................................................. 6-9
6.5. Parts List For New Mounting Base For PN-152SO Relays .................................................... 6-11
List of Figures
Figure 2-1. Typical Plug-in Relay and Mounting Base.............................................................................. 2-1
Figure 2-2. Receptacle Contact Springs Installed .................................................................................... 2-3
Figure 4-1. Circuit for Preliminary Calibration ........................................................................................... 4-2
Figure 4-2. Wiring, Facing the Front of the Relay ..................................................................................... 4-3

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 iv
Figure 4-3. Final Calibration...................................................................................................................... 4-4
Figure 6-1. PN-152SO Internal Parts Location (Sheet 1 of 3) (Dwg. D66000-33).................................... 6-3
Figure 6-2. PN-152SO Part Details (Unit “A”) ........................................................................................... 6-7
Figure 6-3. PN-152SO Part Details (Unit “B”) ........................................................................................... 6-8
Figure 6-4. PN-152SO Base and Test Plugs .......................................................................................... 6-10
Figure 6-5. New Mounting Base for PN-152SO Relays.......................................................................... 6-12
List of Tables
Table 1-1. Electrical Specifications ........................................................................................................... 1-2
Table 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 Vital Relay
(see Figure 5-1) .................................................................................................................... 5-7
Table 5-5. Contact Assembly Section Parts List....................................................................................... 5-9
Table 5-6. Old Style Mounting Base for PC-250B Relays Parts List ......................................................5-10
Table 5-7. Improved Mounting Base (N438689-003) for PC-250B Relays Parts List ............................ 5-12

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 1-1
1. INTRODUCTION
1.1. Introduction
In the PN-150 line of relays the PN-150SO is the equivalent of the ORP-66 D.C. switch
overload relay. It is furnished primarily for the overload protection of high voltage D. C.
switch machines. This relay can be used also to protect low voltage D. C. switch
machines under the same current conditions. This relay, with a different thermal
resistor, can be furnished to match a motor with another D. C. current range.
The operating relay coil, paralleled by a thermal resistor, is in series with the motor.
When the motor current becomes excessive, the operating relay picks up. This picks up
the stick relay, which then releases the operating relay and deenergizes the switch
control relay, thereby opening 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 before placing the relay into
service. Failure to assure proper function of this relay could
result in severe personal injury or death.
The shock indicator (P/N J680167-0012) shows red when the relay has been subjected
to shock in excess of a safe level (i.e., 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, recalibrated, and tested according to
specifications by a qualified individual.

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 1-2
1.3. Mechanical Specifications
The mechanical specifications shown in Table 1-1 are common to all PN-152SO relays
covered in this manual.
Table 1-1. Mechanical Specifications
Parameter
Value
Dimensions
Height
7-1/16” (17.93 cm)
Width
2-7/16” (6.19 cm)
Depth
8-3/8” (21.27 cm)
Temperature
-40°F (-40°C) to +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 -Electrical Specifications
Part No.
Coil Resistance
(Ohms)
Thermal
Operating Time (+/- 10%)
N322522
Oper.
Stk.
Amps
Sec.
Amps.
Sec.
-802
5.0
750
.046
13
5
15
3
-001
5.0
750
.030
13
10
15
6

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 2-1
2. INSTALLATION
2.1. General
Relays plug directly into a mounting base that is secured to a rack. See Section 2.5 for
proper relay insertion.
2.2. Mounting Base
Secure the mounting base directly to the rack using the hardware furnished. All wiring
terminates at the rear of the mounting base to solderless terminals (contact
receptacles). Mounting base details are shown in Appendix A.
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 are shown in Figure 2-1.
The following data defines the indexing established for relays covered by this manual.
1. The index code always consists of four digits (such as 0001, 0002 or 0101). The
index code is used for both the relay and the indexing plate on the mounting
base.
Figure 2-1. Typical Plug-in Relay and Mounting Base
4C5.0002.00
INDEXING PINS
INDEX PLATE
RELAY
MOUNTING BASE
0123456789

PN-152SO Switch Overload Relay
Copyright 2019 SM 5929 Rev. 23, March 2019 2-2
2. The index codes for each relay can be determined from the relay part number
and its suffix that is marked on the nameplate attached to the front of the relay.
The first two digits of the index code are the last two digits of the part number,
and the second two digits of the index code are the last two digits of the suffix.
The index number should agree with the placement of the indexing pins in the
numbered vertical rows on the back of the relay, starting with the top pin and
reading down.
3. The index code for each mounting base is determined by the placement of the
holes in the numbered vertical rows of the large white nylon indexing plate that is
affixed 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. Discard
the indexing plate that comes in a bag tied to the handle of all new relays, unless
it is needed for replacement or a damaged indexing plate or for application to a
new mounting base.
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 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 will accommodate one or two #14 or
#16 wires. It can, however, be equipped with receptacle contact springs for one or two
#10 or #12 wires (J680181), or for one or two #18 or #20 wires (J680179). Make certain
which type of solderless receptacle contact springs accompanies the mounting base
before proceeding with their installation.
2.4.2. Improved One-Piece Base Only (N451376-0302)
The new one piece mounting base with hardware includes a full complement of
receptacle contact springs (M451142-2702) to accommodate one or two #14-#16 wires,
mounting fasteners and tags. It can, however, be equipped with receptacle contact
springs for one or two #10-#12 wires (M451142-2703), or for one or two #18-#20
(M451142-2701). Make certain which type of solderless receptacle contact springs
accompanies the mounting base before proceeding with their installation.
Each solderless receptacle contact spring should be inspected for physical damage
before proceeding with installation.
The following is recommended when installing solderless receptacle contact springs
after crimping wires: