Professional Documents
Culture Documents
CONTENTS SAFETY SECTION 1 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 4 4.1 4.1.1 4.1.2 5 6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 7 8 DESCRIPTION INSTALLATION General Relay mounting Unpacking Storage Site COMMISSIONING Commissioning preliminaries Electrostatic discharges Inspection Wiring Earthing Insulation DANGER Commissioning tests Test equipment Relay CT shorting switches Auxiliary supply Plug bridge check Tap setting multiplier Timing tests Final setting check Final checks SETTINGS Settings Time delay Current setting MAINTENANCE PROBLEM ANALYSIS Procedure Removal of the relay from its case Current transformer check Transistor TR4 (not 30V models) Output relay and non volatile led indication Printed circuit board SPARES COMMISSIONING TEST RECORD REPAIR FORM 5 9 9 9 9 9 9 10 10 10 10 10 10 11 11 11 11 11 11 11 12 12 13 13 13 14 14 14 14 14 14 14 14 14 15 15 15 15 19 21
SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment. Health and safety The information in the Safety Section of the product documentation is intended to ensure that products are properly installed and handled in order to maintain them in a safe condition. It is assumed that everyone who will be associated with the equipment will be familiar with the contents of the Safety Section. Explanation of symbols and labels The meaning of symbols and labels which may be used on the equipment or in the product documentation, is given below.
Functional *earth terminal. Note: this symbol may also be used for a protective/ safety earth terminal if that terminal is part of a terminal block or sub-assembly eg. power supply.
*Note: The term earth used throughout the product documentation is the direct equivalent of the North American term ground.
Before energising the equipment it must be earthed using the protective earth terminal, or the appropriate termination of the supply plug in the case of plug connected equipment. Omitting or disconnecting the equipment earth may cause a safety hazard. The recommended minimum earth wire size is 2.5 mm2, unless otherwise stated in the technical data section of the product documentation. Before energising the equipment, the following should be checked: Voltage rating and polarity; CT circuit rating and integrity of connections; Protective fuse rating; Integrity of earth connection (where applicable) Equipment operating conditions The equipment should be operated within the specified electrical and environmental limits. Current transformer circuits Do not open the secondary circuit of a live CT since the high voltage produced may be lethal to personnel and could damage insulation. External resistors Where external resistors are fitted to relays, these may present a risk of electric shock or burns, if touched. Battery replacement Where internal batteries are fitted they should be replaced with the recommended type and be installed with the correct polarity, to avoid possible damage to the equipment. Insulation and dielectric strength testing Insulation testing may leave capacitors charged up to a hazardous voltage. At the end of each part of the test, the voltage should be gradually reduced to zero, to discharge capacitors, before the test leads are disconnected. Insertion of modules and pcb cards These must not be inserted into or withdrawn from equipment whilst it is energised, since this may result in damage. Fibre optic communication Where fibre optic communication devices are fitted, these should not be viewed directly. Optical power meters should be used to determine the operation or signal level of the device.
Older Products
Electrical adjustments Equipments which require direct physical adjustments to their operating mechanism to change current or voltage settings, should have the electrical power removed before making the change, to avoid any risk of electric shock. Mechanical adjustments The electrical power to the relay contacts should be removed before checking any mechanical settings, to avoid any risk of electric shock. Draw out case relays Removal of the cover on equipment incorporating electromechanical operating elements, may expose hazardous live parts such as relay contacts. Insertion and withdrawal of extender cards When using an extender card, this should not be inserted or withdrawn from the equipment whilst it is energised. This is to avoid possible shock or damage hazards. Hazardous live voltages may be accessible on the extender card. Insertion and withdrawal of heavy current test plugs When using a heavy current test plug, CT shorting links must be in place before insertion or removal, to avoid potentially lethal voltages.
Technical Specifications
Protective fuse rating The recommended maximum rating of the external protective fuse for this equipment is 16A, Red Spot type or equivalent, unless otherwise stated in the technical data section of the product documentation. Insulation class: IEC 61010-1: 1990/A2: 1995 Class I EN 61010-1: 1993/A2: 1995 Class I Installation Category (Overvoltage): IEC 61010-1: 1990/A2: 1995 Category III EN 61010-1: 1993/A2: 1995 Category III This equipment requires a protective (safety) earth connection to ensure user safety. Distribution level, fixed installation. Equipment in this category is qualification tested at 5kV peak, 1.2/50s, 500, 0.5J, between all supply circuits and earth and also between independent circuits. Compliance is demonstrated by reference to generic safety standards. Compliance with the European Commission Low Voltage Directive. Compliance is demonstrated by reference to generic safety standards.
Environment:
IEC 61010-1: 1990/A2: 1995 Pollution degree 2 EN 61010-1: 1993/A2: 1995 Pollution degree 2 73/23/EEC
Product safety:
Section 1.
DESCRIPTION
The MCSU is a sensitive earth fault relay which can be applied to detect earth fault currents down to 0.5% of the current transformer nominal current. An adjustable time delay ensures stability during switching and other transient disturbances and allows adequate grading with other protection systems at high fault current levels. The relay will reset at a current only marginally below pick-up level, permitting a setting level just above the maximum residual current at the fundamental frequency. The MCSU 01 may be used in conjunction with a METI 13 (see Publication R8003) to form a directional earth fault scheme. This scheme uses the directional control terminals 21 and 22 to inhibit the operation of the MCSU 01. When a short is applied to terminals 21 and 22, current from the transformer secondary is diverted from the measuring circuits into the short; thus inhibiting the MCSU 01 from operating. See Publication R6018.
Section 2.
2.1
INSTALLATION
General Protective relays, although generally of robust construction, require careful treatment prior to installation and a wise selection of site. By observing a few simple rules the possibility of premature failure is eliminated and a high degree of performance can be expected.
2.2
Relay mounting The relays are either despatched individually or as part of a panel/rack mounted assembly in cartons specifically designed to protect them from damage. Relays should be examined immediately they are received to ensure that no damage has been sustained in transit. If damage due to rough handling is evident, a claim should be made to the transport company concerned immediately, and ALSTOM T&D Protection & Control should be promptly notified. Relays which are supplied unmounted and not intended for immediate installation should be returned to their protective polythene bags.
2.3
Unpacking Care must be taken when unpacking and installing the relays so that none of the parts are damaged or their settings altered, and must only be handled by skilled persons. Relays should be examined for any wedges, clamps, or rubber bands necessary to secure moving parts to prevent damage during transit and these should be removed after installation and before commissioning. Relays which have been removed from their cases should not be left in situations where they are exposed to dust or damp. This particularly applies to installations which are being carried out at the same time as constructional work.
2.4
Storage If relays are not installed immediately upon receipt they should be stored in a place free from dust and moisture in their original cartons and where de-humidifier bags have been included in the packing they should be retained.
9
The action of the de-humidifier crystals will be impaired if the bag has been exposed to ambient conditions and may be restored by gently heating the bag for about an hour, prior to replacing it in the carton. Dust which collects on a carton may, on subsequent unpacking, find its way into the relay; in damp conditions the carton and packing may become impregnated with moisture and the de-humidifying agent will lose its efficiency. The storage temperature range is 25C to +70C. 2.5 Site The installation should be clean, dry and reasonably free from dust and excessive vibration. The site should preferably be well illuminated to facilitate inspection. An outline diagram is normally supplied showing panel cut-outs and hole centres. For individually mounted relays these dimensions will also be found in publication R6017. Publication R7012, Parts Catalogue and Assembly Instructions, will be useful when individual relays are to be assembled as a composite rack or panel mounted assembly. Publication R6001 is a leaflet on the modular integrated drawout system of protective relay. Publication R6014 is a list of recommended suppliers for the pre-insulated connectors.
Section 3.
3.1 3.1.1
COMMISSIONING
Commissioning preliminaries Electrostatic discharges The relay uses components which could be affected by electrostatic discharges. When handling the module, care should be taken to avoid contact with components and connections. When removed from the case for storage, the module should be placed in an electrically conducting anti-static bag.
3.1.2
Inspection Carefully examine the module and case to see that no damage has occurred during transit. Check that the relay serial number on the module, case and cover are identical and that the model number and rating information are correct. Carefully remove any elastic bands/packing fitted for transportation purposes.
3.1.3
Wiring Check that the external wiring is correct to the relevant relay diagram and scheme diagram. The relay diagram number appears inside the case. Particular attention should be paid to the correct wiring and value of any external resistors indicated on the wiring diagram/relay rating information. Note the shorting switches shown on the relay diagram are fitted internally across the relevant case terminals and close when the module is withdrawn. It is essential that such switches are fitted across all CT circuits. If a test block type MMLG is provided, the connections should be checked to the scheme diagram, particularly that the supply connections are to the live side of the
10
test block (coloured orange) and with terminals allocated with odd numbers (1, 3, 5, 7 etc). The auxiliary supply voltage to the scheme should be routed via test block terminals 13 and 15. 3.1.4 Earthing Ensure that the case earthing connection above the rear terminal block is used to connect the relay to a local earth bar. 3.1.5 Insulation The relay and its associated wiring, may be insulation tested between: all electrically isolated circuits all circuits and earth An electronic or brushless insulation tester should be used, having a dc voltage not exceeding 1000V. Accessible terminals of the same circuit should first be strapped together. Those deliberate circuit earthing links which are removed for the tests, must subsequently be reconnected. 3.1.6 DANGER DO NOT OPEN THE SECONDARY CIRCUIT OF A CURRENT TRANSFORMER. THE HIGH VOLTAGE PRODUCED MAY BE LETHAL AND COULD DAMAGE INSULATION. When the type MMLG test block facilities are installed, it is important that the sockets in the type MMLB 01 test plug, which correspond to the CT secondary windings, are LINKED BEFORE THE TEST PLUG IS INSERTED INTO THE TEST BLOCK. Similarly, a MMLB 02 single finger test plug must be terminated with an ammeter BEFORE IT IS INSERTED to monitor CT secondary currents. 3.2 3.2.1 Commissioning tests Test equipment 1 1 1 1 3.2.2 Variable voltage auto transformer, eg Variac Variable resistor Two pole switch ac ammeter
An overcurrent test set with timing facilities may be used if preferred. Relay CT shorting switches With the relay removed from its case, check that the CT shorting switch is closed by injecting rated current into the neutral circuit. The rated current of the relay (In) is either 1A or 5A as shown on the bottom handle strip of the relay module. 3.2.3 Auxiliary supply With the relay removed from its case, the incoming supply should be checked at the relay case terminals. The incoming voltage must be within the range specified on the rating strip. If a dc auxiliary supply is used then relay case terminal 13 should be positive with respect to terminal 14. For secondary injection testing using test block type MMLG, insert test plug type MMLB01 with the required main CT shorting links fitted. Isolate the relay trip and
11
alarm circuits. Insert the module and connect the auxiliary supply to the relay. It may then be necessary to link across the front of the test plug to restore the auxiliary supply to the relay. 3.2.4 Plug bridge check Set the multiplier to 1.0. Set the relay time delay to 1 second. Inject ac current into the relay current terminals slowly increasing the current until the relay picks up. Check each plug position with/without the plug removed to ensure that the top tap (8%) is selected and that the main CT will not be open circuited. The current pick-up range is shown in the table below. Note: No allowance has been made for instrument errors in measurement of the ac current. AC current operative level (mA) Tap setting 0.5% 1% 2% 4% 8% 3.2.5 Tap setting multiplier Set the relay time delay to 1 second. The plug bridge can be on any setting but for ease of measuring the following positions are recommended. See the table below. Inject ac current into the relay current terminals, slowly increasing the current until the relay picks up. Check each multiplier setting. The current pick up range for the recommended tap settings is shown in the table below but it must be noted that no allowance has been made for instrument errors in measurement of the ac current. AC current operating level (mA) Multiplier Setting 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Is% 4.4 4.8 5.2 5.6 6.0 6.4 6.8 7.2 7.6 In = 1A Plug setting = 4% Pick-up range 41.8 46.2 45.6 50.4 49.4 54.6 53.2 58.8 57 63 60.8 67.2 64.6 71.4 68.4 75.6 72.2 79.8 Is% 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 In = 5A Plug setting = 1% Pick-up range 52.25 57.75 57 63 61.75 68.25 66.5 73.5 71.25 78.75 76 84 80.75 89.25 85.5 94.5 90.25 99.75 In = 1A 4.75 5.25 9.5 10.5 19 21 38 42 76 84 In = 5A 23.75 26.25 47.5 52.5 95 105 190 210 380 420
12
3.2.6
Timing tests Any plug and multiplier setting may be chosen for this test. Using a typical test circuit as shown in Figure 1, inject ac current of at least 110% Is into the relay with the relay timer set to the values given in the table below. Check the operating times. Operating time range (seconds) Timer setting 01 12 23 34 45 56 67 78 89 90 0.1 to 9.9 0.08 0.12 1.14 1.26 2.185 2.415 3.23 3.57 4.275 4.725 5.32 5.88 6.365 7.035 7.41 8.19 8.455 9.345 8.55 9.45 1 to 99 0.95 1.05 11.4 12.6 21.85 24.15 32.3 35.7 42.75 47.25 53.2 58.8 63.65 70.35 74.1 81.9 84.55 93.45 85.5 94.5
3.2.7
Final setting check This test should be carried out using the required final settings. Inject ac current into the relay and slowly increase to 105% Is to ensure that the relay picks-up. With the relay picked up slowly reduce the ac current to 90% Is and check that the relay has reset. (Drop off.) At this stage a final visual check of the settings should be carried out and the cover put into position. Check that the LED resets. Using the typical circuit, check that the operating time of the relay is within the claimed tolerance of 5% or 0.02S whichever is the greater. Check that the LED indicator has operated and resets when the ac current has been removed.
3.2.8
Final checks Operate the relay with the trip and alarm links restored to ensure that the necessary trip and alarm circuits are energized according to the relevant schematic diagram. Disconnect test circuits, and test plugs, and remove any main CT short circuits. CAUTION: If test block MMLG has been used it is essential that the test block cover is replaced to put the relay in service.
13
Section 4.
4.1 4.1.1
SETTINGS
Settings Time delay The operating time of the relay is adjusted by the upper two thumbwheel switches. Time ranges are: 0.1 9.9 seconds in steps of 0.1 second or 1 99 seconds in steps of 1 second 00 is a non-allowable setting.
4.1.2
Current setting The setting current, as a percentage of relay rated current, is set by the plugbridge, which gives coarse adjustment (0.5, 1, 2, 4, 8% In), and the lower thumbwheel switch which acts as a setting multiplier over the range 1.0 1.9 in steps of 0.1. eg. For a required setting of 3.5%: Set plugbridge to next lowest setting, ie. 2%. 3.5% requires a multiplier setting of 1.75, which is not available, so choose between the two nearest points: 1.7 x 2% = 3.4% or 1.8 x 2% = 3.6%
Section 5.
MAINTENANCE
Periodic maintenance is not necessary. However, periodic inspection and test is recommended. It is recommended that commissioning tests 3.2.7 and 3.2.8 are repeated at periodic intervals to check the operation of the relay.
Section 6.
PROBLEM ANALYSIS
It is recommended that faulty printed circuit boards are replaced, and no attempt be made to remove or change components on them. This is because the protective coating on the board is degraded by attempting to solder through it. These instructions therefore do not go into sufficient detail to permit the identification of faulty components at printed circuit board level. 6.1 6.1.1 Procedure Removal of the relay from its case To remove the relay from its case loosen the cover nuts and remove the cover. The relay can now be withdrawn from the case by pulling on the handles. 6.1.2 Current transformer check Disconnect the CT secondary from the board by disconnecting the wire to terminal 1 on pcb ZJ0039.
14
Connect an ac milliammeter between the red and black leads and inject rated current into relay terminals 27 and 28. Measure the secondary current for each position of the plugboard tap selector on the relay front panel. Currents should be within 5% of the values shown in the table below. Tap % 0.5 1 2 4 8 Current mA 20 10 5 2.5 1.25
If these currents are correct, reconnect the CT to the board with the red lead in pin 1. 6.1.3 Transistor TR4 (not 30V models) This is the series voltage regulator transistor which is fitted to all except 30V models. When fitted it is mounted on a heatsink in the ventilated enclosure at the rear of the relay. Apply rated auxiliary volts and measure the dc voltage across electrolytic capacitor C18. If this is not approximately 30V then disconnect TR4 at pcb ZJ0039 terminal 7 and measure the dc voltage across diode D16. If this is approximately 30V then TR4 is defective and should be replaced. 6.1.4 Output relay and non volatile LED indication Set time delay to minimum. Inject a current above setting into the relay. If the ouput relay fails to operate measure the voltage between terminals 9 and 10 on pcb ZJ0039. This should be 24V for 110/125V and 48/54V rated relays and 12V for 27/34V rated relays. If volts are present but the ouput relay does not pick up, replace the pcb ZG1001. Otherwise the fault is on pcb ZJ0039. If the LED does not illuminate or will not reset measure the voltage between terminals 9 and 11 on pcb ZJ0039. This should be 30V on 110/125V and 48/54V rated relays and the input voltage less 2V on 27/34V relays. If this voltage is correct, replace ZG1001 otherwise replace ZJ0039. 6.1.5 Printed circuit board Any fault which cannot be traced to the current transformer, miniature relay or transistor TR4 may safely be assumed to be on the printed circuit board, in which case the relay should be returned to ALSTOM Protection & Control for repair. Should the need arise for the equipment to be returned to ALSTOM T&D Protection & Control for repair, then the form at the back of this manual should be completed and sent with the equipment together with a copy of any commissioning test results.
Section 7.
SPARES
When ordering any spares the serial number and model number of the relay should be included with the order.
15
Stop
Start
16
A
13
Auxiliary
14
27
ct
28
Variable Resistor
A B C C Phase Rotation 27 28 Alternative Connections for Core Balance CT 28 27 Alternative Connections for Neutral CT B B C
P1 A A A
P2
S1
S2
(See Note 3) x Is
27
1
9 9
t secs OP
28
21
Directional Control
22
17
CT SHORTING LINKS MAKE BEFORE (b) & (c) DISCONNECT SHORT TERMINALS BREAK BEFORE (c). LONG TERMINALS
CASE EARTH
5 1 RL1-1 3
Output Contacts
13
14
NOTE 1
(a)
6 2 RL1-2 4
(b)
21
22
(c)
NOTE 2
27
28
NOTE 3
18
Section 8
30/34V _______ 48/54V _______ 63/70V _______ 110/125V ______ 110/127V ________ Test Results 3.1.2 3.2.2 3.2.3 3.2.4 Visual inspection Relay CT shorting switches Auxiliary supply Current setting check Time delay setting 1 second ____________ Multiplier setting 1.0 Tap setting % Pick up current mA Tap setting % Pick up current mA 3.2.5 Multiplier Tap setting Multiplier Pick up current mA Multiplier Pick up current mA __________ % 1.1 1.2 1.3 ________ 1.8 ________ 1.4 1.5 0.5 1 ______________ 8 ______________ _____________ 2 _____________ Plug removed _____________ ___________ ___________ _____________ V dc _________ ac ________
______________ 4 ______________
________ ________
19
3.2.6
Timing tests Is _______ mA Applied current 110% Is 01 _______ 56 _______ 12 _______ 67 _______ 23 _______ 78 _______ 34 _______ 89 _______ 45 _______ 90 _______
Timer setting Actual time in seconds Timer setting Actual time in seconds 3.2.7 Final Setting Is Multiplier Pick up @ 105% Is Operating time
% seconds
seconds
Commissioning Engineer
Customer Witness
Date
20
Date
REPAIR FORM
Please complete this form and return it to ALSTOM T&D Protection & Control Ltd with the equipment to be repaired. This form may also be used in the case of application queries.
ALSTOM T&D Protection & Control Ltd St. Leonards Works Stafford ST17 4LX, England For: After Sales Service Department _________________________ Model No: __________________ Serial No: __________________
Customer Ref:
What parameters were in use at the time the fault occurred? AC volts DC volts AC current Frequency _____________ Main VT/Test set _____________ Battery/Power supply _____________ Main CT/Test set _____________
2. 3. 4.
Which type of test was being used? ____________________________________________ Were all the external components fitted where required? (Delete as appropriate.) List the relay settings being used ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Yes/No
5.
continued overleaf
21
6.
7.
When did the fault occur? Instant Time delayed By how long? Yes/No Yes/No ___________ Intermittent Yes/No
(Delete as appropriate).
8.
What indications if any did the relay show? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
9.
10. Any other remarks which may be useful: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
22
23
A L S T O M T & D P r o t e c t i o n & C o n t r o l L t d St Leonards Works, Stafford, ST17 4LX England Tel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232 Email: pcs.enquiries@tde.alstom.com Internet: www.alstom.com
1999 ALSTOM T&D Protection & Control Ltd Our policy is one of continuous product development and the right is reserved to supply equipment which may vary from that described.
Publication R8018E
Printed in England.