W-400 Transformer Series - Hitachi Rail STS...SM 5994 1000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006 W-400 Transformer Series STS USA Part Nos

SM 5994 1000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006

W-400 Transformer Series

STS USA Part Nos. N451428-0101 to N451428-0115

Installation

Operation

Troubleshooting


Copyright 2019 SM 5994, Rev. 4, March 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

This Class A digital apparatus complies with Canadian ICES-003.

CET appareil numerique de la classe A est conforme a la norme NMB-003 du Canada.


Copyright 2019 SM 5994, Rev. 4, March ii

Revision History

REV. DATE NATURE OF REVISION

0 February 1979 Initial Issue

1 March 2002 Updated to current Service Manual format. Corrected minor errors.

2 June 2008

Updated to current Service Manual format. Evaluated and incorporated ECOs as applicable: EE-1758 (6/03), EE-1804 (11/03 - N/A), EE-1811 (12/03), and K-0265 (9/05 - N/A).

3 May 2014 Information added to Table 1-1, Section 2.3.2.1, Section 2.3.3.1, for part number N452428-0115. Removed Part List.

4 March 2019 Hitachi Rail STS Branding


Copyright 2019 SM 5994, Rev. 4, March iii

Table of Contents 1. INTRODUCTION ................................................................................................................................ 1-1

1.1 General Description .................................................................................................................. 1-1

1.2 Electrical Specifications ............................................................................................................ 1-1

1.2.1 Dielectric Strength ........................................................................................................ 1-2

1.2.2 Ratings .......................................................................................................................... 1-2

1.2.3 Insulation ....................................................................................................................... 1-2

1.3 Mechanical Specifications ........................................................................................................ 1-2

1.3.1 Operating Temperature Range ..................................................................................... 1-2

1.3.2 Weight ........................................................................................................................... 1-2

1.4 AREMA Compliance ................................................................................................................. 1-2

2. OPERATION AND INSTALLATION ................................................................................................. 2-1

2.1 General ..................................................................................................................................... 2-1

2.2 Ratings ...................................................................................................................................... 2-1

2.3 Winding Arrangements and Adjustments ................................................................................. 2-1

2.3.1 Winding Arrangements ................................................................................................. 2-1

2.3.2 Input Terminal Designations ......................................................................................... 2-1

2.3.3 Output Terminal Designations and Adjustments .......................................................... 2-2

2.4 Terminal Board Drawings and Schematic Diagrams ................................................................ 2-4

2.5 Installation Procedure ............................................................................................................. 2-19

3. MAINTENANCE ................................................................................................................................. 3-1

3.1 Preventive Maintenance ........................................................................................................... 3-1

3.2 Corrective Maintenance ............................................................................................................ 3-1

4. RAIL TEAM AND TECHNICAL SUPPORT ...................................................................................... 4-1


Copyright 2019 SM 5994, Rev. 4, March iv

List of Figures Figure 2-1. N451428-0101 Terminal Faceplate and Schematic Diagram .......................................... 2-4 Figure 2-2. N451428-0102 Terminal Faceplate and Schematic Diagram .......................................... 2-5 Figure 2-3. N451428-0103 Terminal Faceplate and Schematic Diagram .......................................... 2-6 Figure 2-4. N451428-0104 Terminal Faceplate and Schematic Diagram .......................................... 2-7 Figure 2-5. N451428-0105 Terminal Faceplate and Schematic Diagram .......................................... 2-8 Figure 2-6. N451428-0106 Terminal Faceplate and Schematic Diagram .......................................... 2-9 Figure 2-7. N451428-0107 Terminal Faceplate and Schematic Diagram ........................................ 2-10 Figure 2-8. N451428-0108 Terminal Faceplate and Schematic Diagram ........................................ 2-11 Figure 2-9. N451428-0109 Terminal Faceplate and Schematic Diagram ........................................ 2-12 Figure 2-10. N451428-0110 Terminal Faceplate and Schematic Diagram ........................................ 2-13 Figure 2-11. N451428-0111 Terminal Faceplate and Schematic Diagram ........................................ 2-14 Figure 2-12. N451428-0112 Terminal Faceplate and Schematic Diagram ........................................ 2-15 Figure 2-13. N451428-0113 Terminal Faceplate and Schematic Diagram ........................................ 2-16 Figure 2-14. N451428-0114 Terminal Faceplate and Schematic Diagram ........................................ 2-17 Figure 2-15. N451428-0115 Terminal Faceplate and Schematic Diagram ........................................ 2-18

List of Tables Table 1-1. Electrical Specifications ................................................................................................... 1-1


Copyright 2019 SM 5994, Rev. 4, March 1-1

1. INTRODUCTION

1.1 General Description

The W-400 transformer series is designed for general voltage adjustment, except for N451428-0110 and -0111, which have special applications. N451428-0110 is a decoding transformer for wayside coded track circuits. N451428-0111 is an indication transformer for coded Centralized Traffic Control (CTC) systems.

W-400 transformers are designed for indoor rack, wall, or shelf mounting. Electrical connections are made to Association of American Railroads (AAR) terminals. Terminal designations and secondary output adjustments are indicated on the terminal faceplates of the units.

1.2 Electrical Specifications

Electrical specifications for the transformers are listed in Table 1-1. This information is also indicated on the terminal faceplates of the units (see Figure 2-1 through Figure 2-14).

Table 1-1. Electrical Specifications

Part No. N451428

Trans. Type

Primary (Input) Secondary (Output) Total Power Rating

(W) Voltage Freq. (Hz) No.

1 (Vac/A)

2 (Vac/A)

3 (Vac/A)

4 (Vac/A)

-0101 General 120/114 Vac 60/100 1 18/20 - - - 360 -0102 General 120/114 Vac 60/100 2 18/10 18/10 - - 360 -0103 General 120/114 Vac 60/100 4 6/3 6/3 25/5 16/12 353 -0104 General 120/114 Vac 60/100 3 12/12 12/10 12/10 - 384 -0105 General 120/114 Vac 50/100 2 16/10 16/10 - - 320 -0106 General 240/228 Vac 60/100 2 18/10 18/10 - - 360 -0107 General 120/114 Vac 50/100 2 32/5 32/5 - - 320 -0108 General 120 Vac 60/100 2 18/3.5 18/3.5 - - 126 -0109 General 240/228 Vac 60/100 1 18/20 - - - 360 -0110 Decoding 10 Vdc 1.25/3 - - - - - - -0111 Indication - - - - - - - - -0112 General 120/114 Vac 60/100 2 18/10 36/5 - - 360 -0113 General 120/114 Vac 60/100 1 18/20 - - - 360 -0114 General 120 Vac 60/100 1 11.3/18 - - - 200 -0115 General 120/114 Vac 60/100 2 18/10 18/10 - - 360



1.2.1 Dielectric Strength

W-400 Transformers are designed to provide AREMA-specified 3000 Vac isolation between primary and secondary windings and between windings and core.

1.2.2 Ratings

Output current is limited to maximum current as shown in Table 1-1 for maximum voltage output. The input voltage must be full line voltage (120, 240, etc.) at rated frequency for maximum output rating.

1.2.3 Insulation

Insulation is Class A.

1.3 Mechanical Specifications

1.3.1 Operating Temperature Range

The operating temperature range of the transformer is -40°F to +160°F.

1.3.2 Weight

The weight of a transformer is approximately 18.5 lb.

1.4 AREMA Compliance

The W-400 transformer series complies with all current AREMA specifications.



2. OPERATION AND INSTALLATION

2.1 General

Terminal identification drawings and schematic diagrams for the W-400 transformers are shown in Figure 2-1 through Figure 2-14. Input/output voltages are listed in Table 1-1. Transformer connection and installation information is provided in this section. Product support contact information is in Section 4.

2.2 Ratings

See Section 1.2 for input/output ratings.

2.3 Winding Arrangements and Adjustments

2.3.1 Winding Arrangements

See Figure 2-1 through Figure 2-14 for terminal faceplate drawings and schematic diagrams for each transformer. Internal windings are connected to the terminals as shown on the terminal boards of the transformers.

For the following example, refer to the terminal faceplate drawing for transformer N451428-0101 illustrated in Figure 2-1. A connection for the complete primary winding is shown across terminals +lP and 3P with a tap at 2P. From terminal +A to terminal D is a complete secondary winding with taps at B and C. No internal connections exist between the P terminals and the A to D terminals; thus, no connections are shown on the terminal board.

2.3.2 Input Terminal Designations

2.3.2.1 Transformers N451428-0101 to -0107, -0109, -0112, -0113, -0115

Input primary windings: +lP, 2P, 3P

2.3.2.2 Transformers N451428-0108, -0110

Input primary windings: +lP, 2P, 3P, 4P.

2.3.2.3 Transformer N451428-0111

No. 1 input primary windings: +lP, 2P. No. 2 input primary windings: 3P, 4P.

2.3.2.4 Transformer N451428-0114

Input primary windings: +1P, 3P. .



2.3.3 Output Terminal Designations and Adjustments

Terminals connected to secondary windings are designated +A, B, C, etc. and terminals connected to associated adjustment windings are designated +W, X, Y, etc. The “+” symbol indicates the start, or instantaneous, polarity of the winding.

When there is more than one secondary winding, the first secondary terminals are designated +lA, lB, lC, etc. and the associated adjustment winding terminals are designated +1W, lX, lY, etc. The second secondary terminals are designated +2A, 2B, 2C, etc. and the associated adjustment winding terminals are designated +2W, 2X, 2Y, etc.

Main and associated secondary adjusting windings are to be used together as a group for the purpose of selecting desired secondary output voltages. In order for the adjustment winding to be additive, the negative terminal of the main secondary winding must be jumpered to the positive terminal of its associated adjusting winding. In similar fashion, sections of main or adjusting windings must also be jumpered together with negatives of main windings being connected to positives of the adjusting windings. For example, to obtain an output of 9.03 V from transformer N451428-0101 (see Figure 2-1), a jumper must be connected from C to X and the outputs taken from terminals B and Y (7.9 + 1.13 = 9.03).

2.3.3.1 Output Terminal Designations for Transformers N451428-0101, -0102, -0105, -0106, -0107, -0109, -0112, -0113, and -0115

Main secondary windings: +A, B, C, D. Secondary adjusting windings: +W, X, Y, Z.

2.3.3.2 Output Terminal Designations for Transformer N451428-0103

No. 1 secondary winding: +lS to 4S. No. 2 secondary winding: +lT to 4T. No. 3 secondary winding: +lR to 6R. No. 4 secondary winding: +lL to 6L.

Each winding is separate and can be connected together for higher voltage output, but output current is limited to the lowest current rating of the combined secondaries.


No. 1 secondary winding: +lR to 4R. No. 2 secondary winding: +lS to 4S. No. 3 secondary winding: +lT to 4T.




No. 1 adjusting winding: +1W to lZ. No. 2 adjusting winding: +2W to 2Z.

The line input is connected to +lP and 4P, and outputs are taken across +lP, 2P, or 3P. For adjusting output voltage, jumper 2P or 3P to the appropriate +1W to lZ or +2W to 2Z sections. For example, to obtain 49.0 V output, jumper from 2P to lX and then connect the output to +lP and lY (40 + 9.0 = 49.0).


No. 1 secondary winding: +lH to 3H. No. 2 secondary winding: +11 to 41.


Secondary winding: +SO to S2000.


Secondary winding: B to Z.



2.4 Terminal Board Drawings and Schematic Diagrams

Figure 2-1 through Figure 2-13 illustrate the terminal faceplates and schematic diagrams for the W-400 transformer series.

STYLE W-400 TRANSFORMER

SECONDARY IS ADJUSTABLEADDITIVELY IN 0.37 V. STEPS

UN451428-0101+ 1P

120/114V. 60/100 Hz.2P

VA3603P

UNION SWITCH & SIGNAL645 RUSSELL ST.BATESBURG, SC 29006

1P

2P

3P

+

+

+

_

_

_

A

B

C

DW

X

Y

Z

SCHEMATICN451428-0101

3E1.

0003

.00

Figure 2-1. N451428-0101 Terminal Faceplate and Schematic Diagram




STYLE W-400 TRANSFORMERUN451428-0102

+ 1P120/114V. 60/100 Hz.

2PVA360

3P


1P

2P

3P

+

+

+

_

_

_

1A

1B

1C

1D1W

1X

1Y

1Z+

+

_

_

2A

2B

2C

2D2W

2X

2Y

2Z

SCHEMATICN451428-01023E1.0

004.

00






1P

2P

3P

+

+

+

+

+

_

_

_

_

_


1L

2L

3L

4L

5L

6L

1R

2R

3R

4R

5R

6R

1S

2S

3S

4S

1T

2T3T

4T

3E1.

0005

.00






1P

2P

3P

+

+

+

+

_

__

_

1R

2R

3R

4R

1S

1T

2S

2T

3S

3T

4S

4T


3E1.

0006

.00




1P

2P

3P

+

+

+

+

+

_

_

_

_

_

1A

2A

1B

2B

1C

2C

1D

2D

1W

2W

1X

2X

1Y

2Y

1Z

2Z




3E1.

0007

.00





1P

2P

3P

+

+

+

+

+

_

_

_

_

_

1A

2A

1B

2B

1C

2C

1D

2D

1W

2W

1X

2X

1Y

2Y

1Z

2Z


008.

00






UN451428-0107

+ 1P

120/114V. 50/100 Hz.

2P

VA320

3P

1P

2P

3P

+

+

+

+

+

_

_

_

_

_

1A

2A

1B

2B

1C

2C

1D

2D

1W

2W

1X

2X

1Y

2Y

1Z

2Z


009.

00




STYLE W-400 TRANSFORMERUN451428-010 8 120V. 60/100 Hz. VA700


1P

2P

3P

4P

+

+

+

_

_

_

1W

1X

1Y

1Z2W

2X2Y

2Z


3E1.

0010

.00






1P

2P

3P

+

+

+

_

_

_

A

B

C

DW

X

Y

Z


3E1.

0011

.00




1P

2P

3P

4P

+

+

+

_

_

_

1I

2I

3I

4I

1H

2H

3H


3E1.

0012

.00






INDICATION TRANSFORMERUN451428-0111STYLE W-400 TRANSFORMER

1P

2P3P

++

+

_ _

_


4P

S0

S300

S1700

S1900

S2000

3E1.

0013

.00






1P

2P

3P

+

+

+

+

+

_

_

_

_

_

1A

2A

1B

2B

1C

2C

1D

2D

1W

2W

1X

2X

1Y

2Y

1Z

2Z

SCHEMATICN451428-01123E1

.001

4.00

ADJUSTABLE IN 0.37 V STEPS

ADJUSTABLE IN 0.75 V STEPS






1P

2P

3P

+

+

+

_

_

_

A

B

C

DW

XY

Z





1P


3P

B

ZSECONDARY

STYLE W-400 TRANSFORMERN451428-0114

+ 1P60/100Hz

3P


B

11.3 V.

Z

PRIMARY

120 V.

3E1.

0001

.00





STYLE W-400 TRANSFORMERUN451428-0115

+ 1P120/114V. 60/100 Hz.

2PVA360

3P


1P

2P

3P

+

+

+

_

_

_

1A

1B

1C

1D1W

1X

1Y

1Z+

+

_

_

2A

2B

2C

2D2W

2X

2Y

2Z


017.

00




2.5 Installation Procedure

WARNING

Disable all power before installing the unit. Failure to do so could result in serious personal injury or loss of life.

WARNING

Install insulating sleeves and insulating nuts as described in Step 3 of the following procedure. Failure to do so could result in serious personal injury or loss of life.

CAUTION

Observe voltage and current limits printed on the terminal board of the transformer. Do not exceed maximum voltages. If these restrictions are not followed, damage to equipment could result.

1. Observe all warning and caution statements listed throughout this manual. Follow the safety policies established for your work site regarding the installation of electronic equipment.

2. Place the transformer in position and secure to equipment rack or mounting surface. Attach wire leads to the AAR terminals.

3. Install insulating sleeves and insulating caps on all AAR terminals.



3. MAINTENANCE

3.1 Preventive Maintenance

WARNING

Before beginning this maintenance procedure, disable all power from the unit and from any nearby circuits. Failure to do so could result in serious personal injury or loss of life.

The transformer should be visually inspected periodically. Examine the condition of the terminal board. Check for loose connections or terminals. Check that the transformer is securely mounted. If excessive dirt is noted on terminals, use a soft, lint-free cloth to remove any accumulated dust or dirt.

3.2 Corrective Maintenance

Maintenance consists of testing for correct output voltages under normal load conditions. If output voltages are incorrect, be sure to test for overloads or incorrect input voltage to the transformer. Information concerning correct input/output voltages for the transformers is located in Table 1-1.



4. RAIL TEAM AND TECHNICAL SUPPORT

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 [email protected].

mailto:railteam@hitachirail



End of Manual

1. Introduction1.1 General Description1.2 Electrical Specifications1.2.1 Dielectric Strength1.2.2 Ratings1.2.3 Insulation

1.3 Mechanical Specifications1.3.1 Operating Temperature Range1.3.2 Weight

1.4 AREMA Compliance

2. Operation and Installation2.1 General2.2 Ratings2.3 Winding Arrangements and Adjustments2.3.1 Winding Arrangements2.3.2 Input Terminal Designations2.3.2.1 Transformers N451428-0101 to -0107, -0109, -0112, -0113, -01152.3.2.2 Transformers N451428-0108, -01102.3.2.3 Transformer N451428-01112.3.2.4 Transformer N451428-0114

2.3.3 Output Terminal Designations and Adjustments2.3.3.1 Output Terminal Designations for Transformers N451428-0101, -0102, -0105, -0106, -0107, -0109, -0112, -0113, and -01152.3.3.2 Output Terminal Designations for Transformer N451428-01032.3.3.3 Output Terminal Designations for Transformer N451428-01042.3.3.4 Output Terminal Designations for Transformer N451428-01082.3.3.5 Output Terminal Designations for Transformer N451428-01102.3.3.6 Output Terminal Designations for Transformer N451428-01112.3.3.7 Output Terminal Designations for Transformer N451428-0114

2.4 Terminal Board Drawings and Schematic Diagrams2.5 Installation Procedure

3. Maintenance3.1 Preventive Maintenance3.2 Corrective Maintenance

4. RAIL Team and Technical Support

Documents

W-400 Transformer Series - Hitachi Rail STS...SM 5994 1000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006 W-400 Transformer Series STS USA Part Nos