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)