Hitachi PV-250 Owner's manual

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

PV-250 Track Relay
Copyright 2019 SM 4574F Rev. 4, March 2019

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 i
Proprietary Notice
This document and the information contained therein are
confidential – the disclosure or other communication,
copying, reproduction and any use whatsoever is forbidden
without the written authorization of Hitachi Rail STS USA,
Inc.
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.
© Property of Hitachi Rail STS USA, Inc., 2019 all rights reserved
1000 Technology Drive, Pittsburgh, PA USA 15219-3120
645 Russell Street, Batesburg, SC 29006
sts.hitachirail.com

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 ii
Revision History
Rev. Date Nature of Revision
* September 1982 Original Issue
* March, 2000 Revision
2 February 2005
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.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 iii
Table of Contents
1. INTRODUCTION ...............................................................................................................................1-1
1.1. Shock Indicators ....................................................................................................................... 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............................................................................................................................ 1-2
1.3.1. Electrical .......................................................................................................................1-2
1.3.2. Mechanical....................................................................................................................1-2
2. INSTALLATION .................................................................................................................................2-1
2.1. General ..................................................................................................................................... 2-1
2.1.1. Care in Handling ...........................................................................................................2-1
2.2. Mounting Base .......................................................................................................................... 2-1
2.3. Relay Indexing .......................................................................................................................... 2-1
2.4. Receptacle Contact Springs ..................................................................................................... 2-3
2.4.1. Old-Style Base Only......................................................................................................2-3
2.4.2. Improved One-Piece Base Only ...................................................................................2-3
2.4.3. Installing Wires in Receptacle Contact Springs ............................................................2-4
2.5. Relay Insertion .......................................................................................................................... 2-5
3. MAINTENANCE.................................................................................................................................3-1
3.1. Periodic Performance Test ....................................................................................................... 3-1
3.1.1. Cleaning........................................................................................................................3-1
3.1.2. Service 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 with Heavy Tarnish, Slightly Rough or Pitted Surface ...................................3-9
3.5.3. Contacts with Surface Film or Oxidation (not Pitted) ....................................................3-9
3.6. Check-Out Procedure (Performance Test)............................................................................... 3-9
3.7. Repairs, Replacement and Adjustment of Relay Components................................................. 3-9
3.7.1. Recommended Tools and Test Equipment ................................................................3-10
3.7.2. Vane Removal ............................................................................................................3-10
3.7.3. Vane Installation..........................................................................................................3-11
3.7.4. Contact Block Replacement and Adjustment .............................................................3-13
3.7.5. Contact and Counterweight Adjustment Procedure....................................................3-14

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 iv
3.7.6. Test for Balanced Magnetic Circuit .............................................................................3-18
4. PARTS LIST ......................................................................................................................................4-1
4.1. PV-250 Track Relay (N342555-809 and N342555-909)........................................................... 4-1
4.2. Contact Block Assemblies (N433482) ...................................................................................... 4-4
4.3. Relay Mounting Base Assembly (N438689-003 and N434647) ............................................... 4-5
4.3.1. New Style Mounting Base (N438689-003)....................................................................4-5
4.3.2. Old Style Mounting Base (N434647).............................................................................4-7
5. RAIL TEAM AND TECHNICAL SUPPORT.......................................................................................5-1
List of Figures
Figure 2-1. Typical Plug-In Relay and Mounting 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 Assembly (N342555-809) ............................................................ 4-3
(For specific contact block arrangement, please refer to Table 4-2, Table 4-3, and Figure 4-2.).............. 4-3
Figure 4-2. Contact Block Assemblies ...................................................................................................... 4-4
Figure 4-3. New Style Mounting Base Assembly (N438689-003) ............................................................. 4-6
Figure 4-4. Old Style Mounting Base Assembly (N434647)...................................................................... 4-8

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 v
List of Tables
Table 1-1. Mechanical Specifications........................................................................................................ 1-2
Table 2-1. Crimping Tools......................................................................................................................... 2-4
Table 3-1. Shop Test Operating Values @ 70-74°F ................................................................................. 3-4
Table 3-2. Operating 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 Base Parts List.......................................................................................... 4-7

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 vi

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 1-1
1. INTRODUCTION
This manual covers the PV-250 Plug-In AC Vane Relay used for track circuit
applications. Since the relay is a two-element AC vane type, it must be provided with
the appropriate equipment to provide the adequate phase displacement between the
local and control (track windings). The earlier and later design relays have the same
operating characteristics and fit into the same mounting base. The design of the PV-
250 Relay conforms to all applicable AREMA specifications.
1.1. Shock Indicators
WARNING
Any relay showing Shock Indicator activation should be
serviced before placing the relay into service. Failure to
assure proper function of this relay may result in severe
personal injury or death.
The shock indicator shows red when the relay was subjected to shock in excess of safe
levels (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 calibrated to operate across a wide environmental range. All moving
parts are enclosed in a sturdy, transparent, dust and moisture-resistant cover. To
ensure 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
This relay uses single-wound coil for the control element and a local element that
presents the impedance to meet the specifications of Table 3-1, Table 3-2, and Table
3-3.
1.2.3. Contacts
Contacts of the PV-250 relay are standard low-voltage silver-to-silver impregnated
carbon front and silver-to-silver back. See Figure 4-2 for an illustration of the contact
block assembly.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 1-2
1.3. Specifications
This manual provides operating values and parts lists specific to PV-250 Track Relay
N342555-809/909. This relay has the following general specifications:
115V Local, 60 Hertz
2F-2B Contacts
Local 0.165 Amperes @ 115 Volts
The following subsections provide the electrical and mechanical specifications of the
PV-250 relays covered in 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 (2½ cm)
Temperature -40°F (-40° C) to +185°F (85°C)
Indexing
5509
Weight 8.0 lbs. (3.63 kg)
Mounting Base
N434647-009 (Old-Style) - 37 oz.
N438689-003 (New-Style) - 18 oz.
Mounting
Base
Dimensions
Height 7-15/16” (20.1 cm)
Width 4-15/16” (12.54 cm)
Depth 2-7/16” (6.19 cm) - (Old Style Base)
Depth 1-29/32” (4.8 cm) – (New Style base)

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-1
2. INSTALLATION
2.1. General
Relays plug directly into a mounting base that is secured to a rack. The only installation
instructions required are for the mounting base.
2.1.1. Care in Handling
It is very important that these vane relays be handled carefully so that undue stresses
are not applied to the vane structure, which might throw the vane out of adjustment. A
piece of twine, which firmly holds the vane, is applied to the relay when it leaves the
factory, via a tapped hole in the rear of the relay. The twine must be removed when the
relay is placed in service. A plug screw 8-32 x ¼ (included) should be installed in this
hole.
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 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 the indexing that has been established for relays covered by
this manual.
a. The index code always consists of four figures (such as 5509) 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 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 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.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-2
INDEX
PINS INDEXING
PLATE
4J1.0021.00
Figure 2-1. Typical Plug-In Relay and Mounting Base
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 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.
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.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-3
2.4. Receptacle Contact Springs
2.4.1. Old-Style Base Only
The N434647 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. However, it can 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
the type of solderless receptacle contact springs that accompany the mounting base
are the appropriate ones before proceeding with their installation.
2.4.2. Improved One-Piece Base Only
The new one-piece mounting base (N438689-003) 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 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 recommended when installing solderless receptacle contact springs
after crimping wires:
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 the lanced tab is slightly compressed as the receptacle contact
spring is inserted along the top of the cavity. The lanced tab could have been
bent during handling and, if so, would not provide the required contact pressure
after the relay is inserted. If the lanced tab does not touch, pull it up slightly using
fingers or a suitable tool.
c. After insertion, pull firmly on the wire to make certain the receptacle contact
spring is locked in the cavity.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-4
Figure 2-2 -Receptacle Contact Springs 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. Table 2-1 identifies the
correct crimping tool to be used when installing wires in a receptacle contact spring.
Table 2-1. Crimping Tools
AMP
Crimping
Tool PN
Wire Size Old-Style Receptacle
Contact Spring
Improved Base Receptacle Contact
Spring
J397138
#10 / #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 receptacle contact spring to hold
it in place. (Do not crush the receptacle contact spring barrel at this time.)
4. 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. When using both terminals, it is more convenient to attach the first wire
to the longest terminal.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-5
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 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 place.

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 2-6

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 3-1
3. MAINTENANCE
This section provides the necessary periodic preventive maintenance procedures that
must be performed to ensure continuous, proper, and efficient operation of the PV-250
style relays covered in this manual. This maintenance section covers periodic
inspections and performance tests.
3.1. Periodic Performance Test
3.1.1. Cleaning
Before inspecting and testing the relay, 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
or common laundry detergent may be used for removal of accumulated dirt, grease,
etc.
3.1.2. Service Requirements
3.1.2.1. General
Track relays must be inspected and tested at least 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.
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.
3.1.2.2. Testing
Calibration Table 3-1 should be used for factory/shop environment only.
Calibration Table 3-3 should be used for field testing relays. This includes initial in-
service testing prior to going into service.
Relays that do not meet test and/or calibration specifications must be removed from
service for shop repair.
3.2. Calibration
3.2.1. Recommended Test Equipment
Two Variable Autotransformers (Variac) - 115 VAC @ 1.0 amp.
AC Ammeter (True RMS)

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 3-2
AC Voltmeter (True RMS)
Resistor - 1500 ohms, ±10%, 25 watts
SPST switch
3.2.2. Shop Calibration Test Procedure
NOTE
When performing calibration, set local voltage as specified
to within ± 1%. When checking relay calibration, current
(Amps) readings are to be used. The voltage range shown in
the table is for REFERENCE ONLY. If the current and the
voltage are measured simultaneously it is possible for one of
the readings to be out of the acceptable range. If this is the
case, as long as the current (Amps) reading is within the
specified range the relay is acceptable.
Connect the circuit shown in Figure 3-1.
1. Set switch S1 to its OFF position.
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 the value indicated on ammeter A; this is the
pick-up current value and should be within the pick-up current range specified in
Table 3-1.
Pick-up (PU) Current Value __________________
7. Again slowly increase the output of Variac T1 until the vane in the relay just
touches the top roller. Record the value indicated on ammeter A; this is the full
stroke current value and should be within the full-stroke current range specified
in Table 3-1.
Full Stroke (FS) Current Value __________________

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 3-3
8. Slowly adjust Variac (T1) to decrease the output until all front contacts of the
relay open. Record the ammeter A reading; this is the drop-away (DA) current
value. It should be within the percentage range, as specified Table 3-1, of the
actual pick-up current value measured in Step 6.
Drop Away (DA) 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 Style Base Contacts Shown without Parentheses
*
115 VAC +1%
*
115 VAC +1%
CAN BE MAINTAINED
WITH VARIAC T2
R**
1500
25W
T2
2
1
FOR
REFERENCE
ONLY
MIN. MAX.
4C5.0027.02

PV-250 Track Relay
Copyright 2019 SM 4574F, Rev. 4, March 2019 3-4
** The resistance value of R is selected to ensure that when the Variac is set to its
Maximum setting the value of current, as measured on meter A, is approx. 10% higher
than the maximum Full Stroke current. For the purposes of this test circuit the resistor
is fixed, however, it can be a potentiometer and set to a value that permits a 10%
higher than the maximum Full Stroke current value.
Figure 3-1. AC Vane Relay Test Circuit
Table 3-1. Shop Test Operating Values @ 70-74
°
F
Vane Torque
(Inch Grains)
Pick-Up (PU) Full Stroke (FS)
Drop Away
% of Actual PU
Volts
(for ref. only)
Amps*
Volts
(for ref. only)
Amps* Shop
325
2.9 – 3.3
0.048 – 0.053
3.3 – 3.6
0.053 – 0.059
85 to 95
Note: Table 3-1 values represent nominal calibration values ±5%. See Table 3-3 for
In-Service and Field Calibration Operating 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 in series with the track winding.
It’s recommended that relays be taken out of service if the Drop-Away falls below the value
shown for field test.
NOTE
Shop Test operating values may be affected by fluctuations
of local voltage, temperature, and test equipment being
used.
Table 3-2. Operating Values at Ideal Phase Relations
(Values shown are for technical use and for calibration tag information only.
Not to be used for normal calibration purposes.)
Pick-Up (PU)
Full-Stroke (FS)
Drop-Away
% of Actual PU
Volts
Amps*
Volts
Amps*
2.60 – 2.88 0.042 – 0.046 2.9 – 3.20 0.047 – 0.052 85 to 95
Note: Table 3-1 values represent nominal calibration values ±5%.