Hitachi PN-150BE User manual

SM 4551L
1000 Technology Drive, Pittsburgh, PA 15219
645 Russell Street, Batesburg, SC 29006
PN-150BE
Biased High Efficiency Vital Relay
STS USA Part No.
N322513-001 N322521-002
N322513-002 N322521-802
N322513-003
Installation
Operation
Maintenance

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 Error! Unknown document property name.4551L Error!
Unknown document property name.1, March 2019

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, 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-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 ii
Revision History
Rev. Date Nature of Revision
0
January 1982
Initial Release
1
March 2019
Hitachi Rail STS Branding

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 iii
Table of Contents
1. GENERAL INFORMATION ...............................................................................................................1-1
1.1. Introduction ............................................................................................................................... 1-1
1.2. Description ................................................................................................................................ 1-1
1.2.1. General .........................................................................................................................1-1
1.2.2. Coils ..............................................................................................................................1-1
1.2.3. Contacts........................................................................................................................1-1
1.3. Specifications............................................................................................................................ 1-1
1.3.1. Electrical .......................................................................................................................1-2
1.3.2. Mechanical....................................................................................................................1-3
2. INSTALLATION.................................................................................................................................2-1
2.1. General ..................................................................................................................................... 2-1
2.2. Mounting Base.......................................................................................................................... 2-1
2.3. RELAY INDELING .................................................................................................................... 2-1
2.4. RECEPTACLE CONTACT SPRINGS ...................................................................................... 2-2
2.4.1. Old Style Base Only......................................................................................................2-2
2.4.2. Improved One Piece Base Only ...................................................................................2-2
2.4.3. Installing Wires in Receptacle Contact Springs............................................................2-3
2.4.4. Base Wiring for Series or Parallel Connected Coils .....................................................2-4
2.5. RELAY INSERTION ................................................................................................................. 2-4
3. FILED 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 .....................................................................................................................4-3
4.1. Introduction ............................................................................................................................... 4-3
4.2. Cleaning and Inspection ........................................................................................................... 4-3
4.2.1. Armature Stop Pin Cleaning .........................................................................................4-3
4.2.2. Cleaning Relay Contacts ..............................................................................................4-4
4.3. Performance Test ..................................................................................................................... 4-5
4.4. REPAIRS AND REPLACEMENT ............................................................................................. 4-6
4.4.1. Disassembly..................................................................................................................4-6
4.4.2. Reassembly ..................................................................................................................4-6
4.4.3. General Parts Replacement .........................................................................................4-6
4.5. ADJUSTMENTS ....................................................................................................................... 4-7
4.5.1. Recommended Tools and Test Equipment ..................................................................4-7
4.5.2. Magnet and Magnet Extension .....................................................................................4-8
4.5.3. Permanent Magnet .......................................................................................................4-8
4.5.4. Indicator ........................................................................................................................4-8
4.5.5. Contact Adjustment ......................................................................................................4-8
4.5.6. Permanent Magnet Hold-Down Force ........................................................................4-11
4.5.7. Polarity).......................................................................................................................4-11
4.5.8. Drop-Away ..................................................................................................................4-12
4.5.9. Pick-Up .......................................................................................................................4-12

PN-150BE Biased High Efficiency Vital Relay
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4.5.10.Working.......................................................................................................................4-12
4.6. CALIBRATION........................................................................................................................ 4-12
4.6.1. Recommended Test Equipment .................................................................................4-12
4.6.2. Procedure ...................................................................................................................4-12
4.6.3. Contact Resistance.....................................................................................................4-14
5. PARTS LIST ......................................................................................................................................5-1
6. RAIL TEAM AND TECHNICAL SUPPORT ......................................................................................6-1
List of Figures
Figure 2-1. Typical Plug-In Relay and Mounting Base ............................................................................. 2-1
Figure 2-2. Receptacle Contact Spring Installed ...................................................................................... 2-3
Figure 2-3. External Connections to Mounting Base ................................................................................ 2-5
Figure 4-1. Armature Stop Pin Location.................................................................................................... 4-4
Figure 4-2. Assembly of Permanent Magnet ............................................................................................ 4-7
Figure 4-3. Heel Contact Springs............................................................................................................ 4-10
Figure 4-4. PN-150BE Relay Test Circuit ............................................................................................... 4-13
Figure 5-1. PN-150BE Relay..................................................................................................................... 5-4
Figure 5-2. Old Style Mounting Base for PM-150BE Relays .................................................................... 5-6
Figure 5-3. Improved Mounting Base for PM-150BE Relays.................................................................... 5-8
List of Tables
Table 1-1. Electrical Specifications ........................................................................................................... 1-2
Table 4-1. Adjustment and Calibration Summary for PN-150BE High Efficiency
Biased Line Relays............................................................................................................... 4-12
Table 4-2. Calibration Values for PN-150BE High Efficiency Relays With
1FB, 1F-1B Ind. L.V. Contacts..............................................................................................
4-13
Table 5-1. Parts List References for PN-150BE Relays ........................................................................... 5-1
Table 5-2. Parts List for PN-150BE Relay ................................................................................................ 5-2
Table 5-3. Parts List for Old Style Mounting Base for PN-150B Relays................................................... 5-5
Table 5-4. Parts List for Improved Mounting Base for PN-150BE Relays ................................................ 5-7

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 1-1
1. GENERAL INFORMATION
1.1. Introduction
This manual provides service information for the PN-150BE plug-in relay. The PN-
150BE relay is a biased high efficiency relay designed for special circuit applications
where voltage losses are critical.
1.2. Description
1.2.1. General
The PN-150BE relay is a high efficiency biased relay which will respond to very low
currents. The coils of this relay may be externally connected in series or multiple to suit
the particular application. This characteristic permits it to be used in series with another
relay, in applications where low currents must be employed to keep voltage loss to a
minimum, or with "UT" timing units.
The relay is factory calibrated to operate across a wide environmental range. All moving
parts are enclosed in a sturdy, transparent, dust and moisture resistant cover. To insure
the relay is inserted in its proper mounting base, all relays have indexing pins. Relays
lock securely in the plug-in position.
1.2.2. Coils
Coil resistance of PN-150BE relay is dependent on part number. Refer to Section 1.3.1
to correlate part numbers to coil resistance values. The resistance selected depends on
the system voltage and circuitry.
1.2.3. Contacts
Contacts of the PN-150BE relay are standard low voltage silver-to-silver impregnated
carbon front and silver-to-silver back. See Figure 5-1 for a pictorial representation of the
contact assembly.
1.3. Specifications
The following paragraphs provide the electrical and mechanical specifications of the
PN-150BE relays covered in this manual.

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 1-2
1.3.1. Electrical
Relay electrical specifications are tabulated in Table 1-1 in part number order.
Table 1-1. Electrical Specifications
Part Number
With Front
Testing Facility
Contacts
Coil Resistance
Ohms Minimum
Drop Away
Volts
Energization System
Voltage
Series Multiple Amps Volts(DC)
N322513-001
1FB, 1F,
1B Std. 60 0.445 0.0148 0.888 *
15
0.222
0.0296
0.444
N322513-002
1FB, 1F,
1B Std. 1000 1.88 0.0038 3.8 10 - 12*
250
0.94
0.0075
1.88
N322513-003
1FB, 1F,
1B Std. 2000 2.78 0.0028 5.56 10 - 24**
500
1.4
0.0056
2.8
N322521-002
1FB, 1F,
1B Std. 2000 -- 3.22 0.0033 6.60 10 - 24***
N322521-8021
1FB, 1F,
1B Std. 2000 -- 3.22 0.0033 6.60 10 - 24***
* Normally used in series with another relay.
** For use in line circuits where voltage losses are critical.
*** For use with "UT" Timing Units.
1
These relays are presently furnished with a Lexan cover. When the present stock
of TYRIL covers is depleted, all PN-150BE covers will be Lexan with molded-in
vent.
Contacts - standard low voltage silver to silver-impregnated carbon front, and
silver to silver back.
Contact Assignments - Contact
Number Type
1 FB
2 B
3 F

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 1-3
1.3.2. Mechanical
The following mechanical specifications are common to all PN-150BE relays covered in
this manual.
Relay 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: Refer to Section 2.3
Weight: 8.25 Lbs. (3.75 kg)
Mounting Base: N349904 (Old Style)
N451376-0302 (Improved Style)
Mounting Base Weight: 17.5 oz. (Old Style)
9.5 oz. (Improved Style)
Mounting Base Dimensions: Height 7-15/16" (20.16 cm)
Width 2-7/16" ( 6.19 cm)
Depth 2-7/16" (6.19 cm) (Old Style Base)
Depth 1-25/32" (4.52 cm) (Improved Base)

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 1-4

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-1
2. INSTALLATION
2.1. General
Relays plug directly into a mounting base which is secured to a rack. The only
installation instructions required are for the mounting base.
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 (receptacle contact
springs).
Mounting base details are shown in Figure 5-2 (Old Style Base) and Figure 5-3
(Improved Base) of Section 5.
2.3. RELAY INDELING
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 which 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.
Figure 2-1. Typical Plug-In Relay and Mounting Base
4C5.0002.00
INDEXING PINS
INDEX PLATE
RELAY
MOUNTING BASE
0123456789

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-2
The following data defines the indexing that has been established for relays covered by
this manual.
a. The index code always consists of four figures (such as 0001, 0002, or 0101)
and is used for both the relay and the indexing plate on the mounting base.
b. The index code for each relay can be determined from the relay part number and
its suffix which is marked on the name plate 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 thus obtained 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.
c. 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 which
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 which comes in a bag tied to the handle of all new relays
unless it is needed for replacement of a damaged indexing plate or for
application to a new mounting base.
WARNING
Never drill new holes in a base indexing plate which 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 which may compromise safety circuit
functions.
2.4. RECEPTACLE CONTACT SPRINGS
2.4.1. Old Style Base Only
The mounting base will normally be equipped with the required quantity of J680165
solderless contact springs receptacle (receptacle springs), and will accommodate one
or two #14 or #16 wires. It can, however, be equipped with receptacles for one or two
#10 or #12 wires (3680181), or for one or two #18 or #20 wires (3680179). Make certain
which type of solderless receptacle contact springs accompany the mounting base
before proceeding with their installation.
2.4.2. Improved One Piece Base Only
The one piece mounting base with hardware (N451376-0302) includes a full
complement of receptacle contact springs (receptacle springs), mounting fasteners, and
tags. Standard solderless receptacle contact springs will accommodate one or two #18 -

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-3
#20 (3680195), two #14 - #16 (3680195-0001), or two #10 - #12 (3680195-0002) wires.
Make certain which type of solderless receptacles contact springs accompany 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:
a. Receptacle contact springs must be inserted into the base with the lock side
down or lanced tab up (Refer to Figure 2-2).
b. Make certain that the lanced tab is slightly compressed as the receptacle contact
spring is inserted along the top of the cavity.
c. After insertion, pull firmly on the wire to make certain the receptacle contact
spring is locked in the receptacle.
Figure 2-2. Receptacle Contact Spring Installed
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. The following table
identifies the correct crimping tool to be used when installing wires in receptacle contact
springs.
RECEPTACLE
SPRING
CONTACT
RECEPTACLE
SPRING
CONTACT
LOCK SIDE LOCK SIDE
OLD MOUNTING BASE IMPROVED MOUNTING BASE
4C5.0003.00

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-4
Crimping Tool
Wire Size
Old Style
Receptacle
Contact Spring
Improved Base
Receptacle
Contact Spring
(T&B Type) (Amp Type)
M451151-0502 J397138 #10 - #12 AWG J680181 J680195-0002
M451151-0501 J397139 #14 - #16 AWG J680165
(Standard)
J680195-0001
M451151-0503
--
#18 - #20 AWG
J680179
J680195
a. Strip 3/16 in. (0.187 in. or 0.47 cm.) of insulation from the end of the wire.
b. Place the receptacle contact spring into the jaws of the proper crimping tool.
c. Partially close the crimping tool jaws against the receptacle contact spring to hold
it in place. (Do not crush the receptacle contact spring barrel at this time.)
d. Insert the stripped end of wire all the way into the receptacle contact spring
barrel. Squeeze the tool handles until crimping is completed and the jaws
release. Always attach the first wire to the longest terminal. This ensures that a
second lead may be attached to the receptacle contact spring at a later time.
e. 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.
2.4.4. Base Wiring for Series or Parallel Connected Coils
PN-150BE relay coils can be either series or parallel connected by externally wiring the
mounting base (see Figure 2-3).
2.5. RELAY INSERTION
Orient the relay to the mounting base with the push rod to the left-hand side; 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 place.

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-5
Figure 2-3. External Connections to Mounting Base
_
_
_
_
+
+
+
+
-A
1
-A
1
+A
1
+A
1
-B
2
-B
2
+B
2
+B
2
CACA
SERIES CONNECTED
SERIES CONNECTED
MULTIPLE CONNECTED
MULTIPLE CONNECTED
(IMPROVED STYLE BASE)
(OLD STYLE BASE)
4C5.0090.00

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 2-6

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 3-1
3. FILED MAINTENANCE
3.1. Introduction
This section provides the necessary periodic preventive maintenance procedures which
must be performed to ensure continuous, proper, and efficient operation of the PC-
150BE relays covered in this manual. Field maintenance covers periodic inspections
and performance tests.
3.2. Periodic Performance Test
3.2.1. Cleaning
Before inspecting and testing the relay, if necessary use a soft cloth to clean the exterior
to remove any dirt or dust that may have collected. A safe cleaning solution of alcohol
and water may be used for removal of accumulated dirt, grease, etc.
3.2.2. Service Requirements
3.2.2.1. General
All vital relays must be inspected and tested at least once every 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.
All vital relays installed in locomotive or car-carried equipment are to be inspected and
tested at least every two (2) years as above. In addition, every four years the relays are
to be removed from service and adjusted, repaired and tested.
Relays not passing the above stated tests and inspections must be replaced and not
returned to service until the operating characteristics and conditions are in accordance
with STS USA specifications.
3.2.2.2. In-Service Test
It is recommended that line relays in service be removed from service for shop repairs
when one or more of the following conditions occur: (Use as a reference the calibration
values given in Table 4-2.)
a. Drop-Away value (D.A.) falls below 67% of the value given.
b. Full-Drop-Away value (F.D.A.) falls below 33% of the value given.
c. Full Stroke value (F.S.) increases to more than 110% of the value given.
3.2.2.3. Test Procedures
Test the operating characteristics of the PN-150BE relays as given in Section 4.6 in this
manual.

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 3-2

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 4-3
4. SHOP MAINTENANCE
4.1. Introduction
This section provides the information necessary to perform shop level repairs of the PN-
150BE relays covered in this manual. In general, relays arriving at the shop for repair
have been checked in the field and have been found to perform unacceptably or have
been physically damaged.
4.2. Cleaning and Inspection
Before inspecting the relay and initiating repairs, use a soft cloth to clean the exterior
carefully to remove any dirt or dust that may have collected. A safe cleaning solution of
alcohol and water may be used for removal of accumulated dirt, grease, etc.
Inspect the relay exterior for signs of physical damage, such as cracked or broken
cover, cracked or damaged housing, and damaged and or missing contact block
terminals and indexing pins. If severe damage is found, a careful inspection of the
interior components should be made for obvious physical damage.
Remove the cover and clean the surface between the armature and the pole faces,
especially the stop pin area, using a lint free cloth and alcohol.
Proceed with stop pin and relay contact cleaning, using the following recommended
cleaning materials:
Recommended Cleaning Materials
Order Reference
Dacron cloth covered metal strip
N378099
Extra Dacron sleeving for recovering three metal
strips
J772330
#4/0 Metallographic paper sheet 9" x 14"
J035215
Burnishing tool
J397187
Lead pencil, soft (non-oil content)
--
Distilled Water
--
4.2.1. Armature Stop Pin Cleaning
The following instructions are for cleaning the armature stop pin (see Figure 4-1). This
procedure should be followed wherever a relay is shopped for failure to meet its
calibration specifications during scheduled field inspection and tests.
1. Insert a clean Dacron Cleaning Tool (N378099) between the stop pin and relay
pole face. Using moderate pressure to hold the armature closed, pull the
cleaning strip back and forth in a circular motion over the stop pin. Continue this
process until it is apparent that no foreign substances are being transferred to the
strip.
2. The next step is to apply a dry lubricant such as graphite (a soft lead, non-oil
content carpenters pencil is suggested) to the relay stop pin and its point of
contact on the pole face.
a. Take a second clean Dacron strip and rub the graphite over both sides of the
strip, liberally impregnating it with graphite to at least half its length.

PN-150BE Biased High Efficiency Vital Relay
Copyright 2019 SM 4551L, Rev. 0 1, March 2019 4-4
Figure 4-1. Armature Stop Pin Location
b. Insert the impregnated strip between the armature stop pin and its point of
contact on the relay pole face. While applying moderate pressure to keep the
armature closed, pull the strip back and forth in a circular motion and continue
for several seconds to ensure a sufficient amount of graphite transfer.
c. It is not necessary to observe a significant deposit of graphite since most of
what is required can only be determined by means of a microscope.
3. Recheck relay calibration and prepare relay for return to service.
4.2.2. Cleaning Relay Contacts
This section covers recommended methods for the preparation and cleaning of relay
contacts.
After contacts have been filed and/or after adjustments have been made to meet
calibration requirements, the contacts should be cleaned in accordance with the
procedure given in Sections 4.2.2.1 and 4.2.2.2.
CAUTION
If it is desired to use an aerosol spray for cleaning relay
contacts, only virgin Freon TF (available from Miller
Stephenson Chemical Co. As MS-180 or MS-230 Contact
Re-Nu Freon TF) is approved by STS USA for cleaning
contacts with the driver attached to the contact springs.
4.2.2.1. General
a. Preliminary information
The Dacron covered washing and drying strips should be used to clean no more
than 12 front (carbon) and 12 back (silver) contacts after which they should be
washed (while still on the metal strip) before re-use. The Dacron cloth covered
metal strips should be cleaned using a mild soap or detergent and water, rinsing
thoroughly and allowing to dry.
SAFETY PINS
STOP PIN
SEE ENLARGED AREA
4C5.0091.00