3 [-GOLDS DIGITAL MOTOR PROTECTION RELAY RELAYS TYPE PBSJ 3E5 N11 INSTRUCTION MANUALSYMBOLS AND DEFINITIONS Ww byly o/h st Vr Vaux 1 Vaux 2 IRF Relay rated current which is 1 amp or 5 amp depending on the input terminals selected. Motor full load current when lo/Iy potentiometer setting is adjusted to take into account the C.T. ratio. Potentiometer setting to match the relay to the motor full load current by taking into account the ratio of the main current transformers adjusted over the range 0.40 to 1.25 x Iy Potentiometer setting for the thermal trip time at 6 x Ip or (6 x FLC) for the cold or starting condition adjusted over the range 5.0 to 60.0 seconds. Potentiometer setting for the instantaneous high set overcurrent as a multiple of relay rated current ly Potentiometer setting for the earth fault as a multiple of relay rated current ly. Reading of negative phase sequence current expressed as a percentage of the maximum line current monitored. Number of recorded motor start ups since energization of the auxiliary power supply. This assumes that the starting current is at least 1.75 xl, or FLC for a minimum duration of 60 ms. Latest start up or run up time of the motor in seconds, with starting conditions as above and the time recorded until the current falls to 1.5 x lo. Thermal trip level Thermal prior overload alarm level. (Through separate relay ‘B’). Undercurrent setting fixed at 40% lq, Connection for rotor speed switch to override the additional stall function. Main auxiliary power supply to terminals 61 and 62. 80 ... 265v AC or DC standard 18... 40v DC only available 0 ... 150v DC only available Auxiliary power supply to terminals 10 and 11 when additional stall or locked rotor protection required(within the same voltage range as the main auxiliary power supply)- Internal relay fault. On applying the auxiliary power supply the relay is continually monitored and in the event of an internal relay fault a ‘O' will be displayed under the Function Indicator ‘T’ and the alarm relay ‘B’ will operate. Maximum monitored line current.GENERAL DESCRIPTION The P&B micro-Golds Digital Motor Protection Relay employs the latest micro computer techniques to give a complete motor protection package for polyphase AC motors. The relay is programmed to provide:~ * Thermal overload protection with adjustable inverse current/time curves. Overload prior alarm (through separate output relay) Locked rotor and stall protection. * High set overcurrent protection Zero phase sequence or earth fault protection Negative phase sequence or phase unbalance protection (inverse time). Undercurrent protection (definite time). Direct numerical readout of all set values, of actual measured running line currents as well as memorized fault information after relay operation. A sophisticated self-supervision system continuously monitors the internal functions of the relay with both hardware and software watchdogs. Outstanding accuracy and long time stability features due to a digital and software based design. High withstand against all types of mechanical and electrical interference and tested according to the latest IEC Standards. The relay has a thermal unit which operates with an I’t inverse current/time characteristic once the thermal current setting has been exceeded by 5%. The inverse current/time characteristics are adjustable through the potentiometer setting tg, to match the majority of motor thermal withstand curves. With the following special features:- 1. Facility to permit a quicker re-start after motor has been running continuously at full load current or less than full load current. In this event, 50 per cent of the relay’s thermal capacity is immediately available for a re-start. 2. When a motor is tripped on overload the thermal capacity available in the relay for a re-start is increased at a rate according to the cooling time constant of the relay. The motor cannot be re-started until 50% thermal capacity is available in the relay as the output relay ‘A’ is sealed in and cannot be reset until this condition is reached. 3. If the motor is started from cold and then stopped, an immediate re-start would only be possible if there was sufficient thermal capacity available within the relay, The thermal capacity used can be reset to zero by depressing push button R, and R; together and switching the auxiliary power supply ‘OFF’ and then ‘ON’. This facility should be used with caution and is of particular use during testing and commissioning Prior overload alarm at 95% of ©, available through output relay ‘B’. 5. Initializing of thermal replica to 94% of ©, on restoration of power supply.The input isolating transformers are mounted in the rear of the case. The power supply unit and output relays are mounted on PCBs behind the left hand fixed facia plate. The measuring unit containing programme switches, setting potentiometers, digital display and reset push buttons is withdrawable. Captive finger screws are provided at the top and bottom of the right hand facia plate of the measuring unit to allow withdrawal. Currents in line L1 and L3 are monitored from Class 10P10 current transformers through terminal connections 1 & 2 and 7 & 8 for 5 amp rating and to terminals 1 & 3 and 7 & 9 for 1 amp rating. Earth fault monitoring is achieved from a core balance current transformer or a residual connection of 3 line current transformers to terminals 25 & 26 for 5 amp rating and to terminals 25 & 27 for 1 amp rating AUXILIARY POWER SUPPLY The relay requires a maintained auxiliary power supply connected to terminals 61 and 62 and can be of any voltage within the range 80 ... 265V AC or DC. This standard internal self regulating power unit can accept most of the voltage levels commonly used in electrical power installations but special power units are available for 18 - 40V DC only and 40 - 150V DC only. The relay is therefore interchangeable with different installations as long as the available power supply voltage levels are within the specified range. The internal power unit provides full insulation between the auxiliary power supply network and the electronic circuits of the relay and forms the stabilized voltages used within the relay. The power unit is self-starting when energized and it is protected against overloads and short circuits. Whenever the main auxiliary power supply is connected or re-connected to the relay the electronic circuitry is reset and initialises the thermal replica to 94% of the tripping level ©, The thermal replica will then increment or decrement exponentially depending on the level of the current input to the relay. An auxiliary power supply (within the same voltage range as the main auxiliary power supply) is only connected to terminals 10 & 11 when additional stall protection is required. The connection I/r provides a facility to employ a rotor speed switch to override the additional stall function and is particularly useful when the energy in terms of Int units expended during motor starting exceeds that of the locked rotor or stall withstand energy level The changeover contacts of relay ‘A’ are shown in the normal running state and will change over on a tripping operation. (See technical specification for contact rating.) The changeover contacts of relay ‘B’ are shown in the state when the relay is not energized. On applying the auxiliary power the contacts will change over and will change back again on an alarm function, SELF SUPERVISION The relay is provided with a sophisticated self-supervision system, which continuously monitors both the hardware and the software of the unit. Output relay ‘B’ operates upon loss of the auxiliary power supply through the N/O contacts 71-72. If an internal supply voltage is lost, the output relay ‘B’ will also operate and the function indicator will display a figure ‘0’ indicating an internal relay fault The functions of the A/D converter and the microprocessor circuits are continuously supervised by means of a hardware watchdog which, in the event of an internal fault, will reset the processor and reinitialise the relay. If the fault persists, the output relay ‘B’ will operate and the function indicator will display a figure ‘0’ indicating an internal relay fault.When the relay is reinitialised, a complete programme memory checksum test is automatically performed and the relay is prevented from operating if this test detects an error. A corresponding software watchdog provides an alarm through output relay ‘B’ if there is a malfunction of the programme execution. The main tripping relay ‘A’ is prevented from operating when an internal relay fault is detected. DIGITAL DISPLAY The LED digital display is located at the top of the measuring unit as illustrated below:- The left hand section of the digital display under the function indicator ‘T’ indicates a single number depending on which display mode is being used. The right hand section of the digital display gives the setting values, the running values and the memorized values just prior to tripping with current values expressed as multiples of relay rating |y. DISPLAY MODE 1. POTENTIOMETER SETTINGS Push button R, is used for potentiometer settings lo/Iy, tew P¥/Iy. lo/Iy and the switch SG1 checksum described in detail later. The values are displayed by stepping through push button R, in the following sequence:- lo/ly Rated Motor Current 0.40... 1.25 x ly 2 tox Thermal trip time at I=6 x Ip 5.0... 60 Secs 3 I> /ly High set overcurrent trip 2.0..12.0 x ly 4 lo/ly Zero Sequence trip current (0.06 x0.6 x I 5 SG1 Switchgroup checksum testDISPLAY MODE 2. INDICATION OF RUNNING AND MEMORIZED VALUES Push button R; is used to provide the running values and the memorized values just prior to tripping. The values are displayed by stepping through push button R, in the following sequence:- 1 1, Current in Phase L1 (x Iy) lis Current in Phase L3 I, Value of Zero Seq. Current |, Value of Neg. Seq. Current (%l) N,, Number of start ups (—) t,, Latest start-up time (SECS) Thermal capacity used (%0,) BOGE The “number of start-ups N,,” is only recorded if the relay detects a motor starting current exceeding 1.75 x FLC for a minimum time of 60ms. The “latest start-up time t,;” is a measurement to a point 100ms after the starting current has reduced to 1.5 x FLC The memorized values are maintained until:- a) Loss of auxiliary power supply to the relay. b) The relay is reset by pressing push buttons R, and R, together. c) The motor is restarted when output relay is selected for auto resetting. NOTE: When the relay is reset all memorized values are cleared except the number of motor start ups and the latest start-up time. DISPLAY MODE 3. TRIP FUNCTION INDICATOR In the event of a trip a single number displayed under the indicator ‘T’ will give the cause of the trip in accordance with the table shown below which is also printed on the relay facia plate:- T FUNCTION INDICATOR 1, er 21>> INST. O/C 3 Ip UB 4 (Ft) STALL 5l< uc 6o& O/L ALARM 7a O/L TRIP 0 IRF INT. RELAY FAULTIn the event of the Trip Function Indicator displaying ‘6’ or ‘0’, overload prior alarm and internal relay fault, the separate alarm relay ‘B’ will operate. The cause of the trip is continuously displayed until:- a) Loss of auxiliary power supply. b) Activation of push buttons R, or Ro. Having established the cause of the trip from the TRIP FUNCTION INDICATOR, Push button R; is pressed to give a digital readout of the motor parameters just prior to tripping as described under Display Mode 2. The relay is reset by pressing PUSH BUTTONS R; and R; fogether. This can only be done when the cover is opened as Push button R; is the only push button accessible from outside the case. DIMENSIONS AND MOUNTING INSTRUCTIONS The relay is housed in a flush-mounted case and can be arranged for semi- flush mounting with the use of a 40mm or an 80mm collar, or raising frame, which reduces the depth behind the panel by the same dimension. * The relay case is made of a black anodized, extruded aluminium profile. A cast aluminium alloy mounting frame with a rubber gasket provides a degree of protection by enclosure to IP 54 when the relay is panel-mounted. The relay case is complete with a hinged gasketed, clear, UV-stabilized polycarbonate cover with a sealable fastening screw. The degree of protection by enclosure for the cover is also IP 54. A terminal block is mounted on the back of the relay case to facilitate all input and output connections. A connection diagram is shown adjacent to the terminal block. To each terminal one or two 2.5mm? wires can be connected. Terminal lugs are not required. 278 33 245» penecnnigagT 2 162 “If required semi-flush raising frames are available to reduce the depth behind the panel.CONNECTION DIAGRAMS Alternative Arrangement For Residually Connected Earth Fault Element cts ws ho cect i. B—- WEF To Motor is -- + — re LB Vaux 2 Alarm relay Trip & alarm relay 4 79 172 Geese 7 ep s9 — | Dy | 1 Digital * a, | — RS rh. : COG, Special CT connections when E/F inhibit required. Notes: (1) C.T. connections are shown for 1A secondaries, (2) RS = stabilising resistor - see note on page 12SETTING UP PROCEDURE PROGRAMME SWITCH SG1 Switch SG1 is an 8 gang switch located between the push button R, and Ry ‘on the measuring unit and each switch has two positions 1 or 0. Each switch position must be selected according to the functions required before putting the relay into operation. so1|/ 1 o $1 | CONT.| C.B | — Contactor/Circuit Breaker Control $2 | 50ms|1 sec.] — Operating Time of Earth Fault Unit $3 | MAN | AUTO] — Auto/Manual resetting of auxiliary tripping relay A S4 | 50% | 75% | — Stall protection time compared to thermal curve S5 | ON | OFF | — Negative phase sequence current protection S6 | ON | OFF | — Prior alarm to relay B at 95% of 8, $7 | ON | OFF | — Undercurrent protection (Output Relay A) fixed at 40% Io $8 | TEST [NORM] — Normal operation/hardware test. — This switch position selects the type of motor switching: contactor or circuit breaker. With the switch S11 in position ‘1’ (contactor) the high set overcurrent unit is inhibited and will not operate and the earth fault is inhibited for currents above 4 x Ip. To ensure that the earth fault inhibit is effective for all earth fault conditions it is essential to use three main current transformers connected residually or with an additional core balance CT as shown in the connection diagrams under ‘General Description’. With the switch S1 in position ‘0’ (circuit breaker) both the high set overcurrent unit and the earth fault unit are operational and it is assumed that the motor switching device can interrupt the prospective short-circuit current and prospective high earth fault currents. — This switch position determines the operating time of the earth fault unit. With switch $2 in position ‘1’ the operating time is typically 50ms and with the switch S2 in position ‘0’ the operating time is 1 second. —This switch position allows a selection of auto or manual resetting of the output tripping relay ‘A’. If the selection is manual resetting the relay is achieved by depressing Push button R, and R, together and in doing so the memorized values prior to tripping are eliminated, except the number of motor start ups and the latest start-up time. If auto resetting is selected the relay will automatically reset and the memorized values held until the motor is re-started. — If the stall facility is connected by applying an auxiliary power supply to terminals 10 and 11 the operating time of the selected thermal curve can be reduced to 50% or 75% of the normal trip times (trip times shown on dotted curve)$5_ —This switch selection provides negative phase sequence current or phase unbalance protection and incorrect phase sequence protection. The relay measures actual negative phase sequence currents and is expressed as a percentage of the maximum current being monitored and will pick up at 15%, The operating characteristic is an inverse curve tripping at 20 seconds at 15%, 5 seconds at 30% and 1.5 seconds at 57%, which corresponds to a single phase or maximum phase unbalance. Negative phase sequence current protection is. blocked below currents equal to 0.25 x |, or FLC. S6_—This switch selection provides prior overload alarm through the separate relay 'B’ and commences at 95% of ®,. This is useful to give an indication when the motor is approaching an overload condition. 7 — This switch selection gives undercurrent protection through output relay ‘A’ and is fixed at 40% Ip (or 40% FLC). When the current drops below this setting the relay will trip in 10 seconds. (Undercurrent protection is blocked below 12% Ig i.e. at motor standstill. This facility is useful for some drives, such as pumps and conveyors where it is, necessary to detect loss of the driven load S8 — This switch selection gives a test position to provide an integrated hardware test of the relay (described later). For normal operation the switch position ‘0’ is selected. Having selected the required switch positions these can be sealed by the insertion of a plastic rod through the holes in the switch toggles. It may be necessary to loosen the facia plate to afford easier access.10 RELAY SETTINGS—PUSH BUTTON R, Press push button R; to select the potentiometer settings in the following sequence:- Li 1 | lo/ly Rated Motor Current 0.40...1.25 x In 2 ] tex Thermal trip time at |=6 x Ip 5.0...60 Secs 5 | SG1 Switchgroup checksum test POTENTIOMETER SETTING I,/ly Press Push Button R, until the number 1 is displayed under the function indicator ‘T’, The setting is adjustable by the appropriate potentiometer over the range 0.40 to 1.25 x ly which is shown on the digital display. The setting lo/ly is to match the relay to the motor full load current and to take into account the ratio of the main current transformers. If, for example, the motor full load current is 200 amps, the main CT ratio 200/5 and the relay rating ly selected at 5 amps; then the setting lp/ly would be 1.0. If however, the motor full load current was only 160 amps, then the setting I¢/ly would be 169= 0.8. 200 This means that Ip = 0.8 ly and is directly proportional to the motor full load current and the current/time characteristic curves |p/t are in fact multiples of motor full load current against time. The very wide setting range allows for bad current transformer matching but it is recommended to try to match the current transformer ratio with the full load current within the range 0.9 to 1.1 x ly as the relay has an accuracy of +1% of the setting value within this range. POTENTIOMETER SETTING tg, The thermal current/time characteristics of the relay allows for an overload setting of 105% or 1.05 x |, (i.e., the pick-up current of the relay is 1.05 x |). If a different trip setting is required, this can be calculated as follows:- Assuming lp =0.8 ly for a trip setting of 105% — a trip setting of 110% 110 105 or a trip setting of 115% p= U8 x08 y=0.88 | = 8 Losty=0: ° "105 2 ‘ 0.8 Iy = 0.84 ly Ip = However, trip times would be different from the curve shown which is for an overload setting of 105%. The trip time can be calculated for various multiples of motor FLC by using the following equations:- 3 | I>>/ly High set overcurrent trip 2.0...12.0 x ly al ly zero sequence trip current 0.06...0.6x ly | ————_—PBCJ 5A1 t= SOM2 t= TSA, (Starting/ Cold Condition) t, = 32.alog, * |) seconds pe where ‘p’ is multiple of motor FLC (per unit value). ‘s’ is overload setting required in per unit value e.g. 105% overload = 1.05. ‘a’. setting of ts, in seconds. operating time in seconds. (Running/Pre-load Condition) 08 (IP seconds pos where |; is steady state load prior to overload condition divided by motor FLC eg. if motor is running at FLC, |, = 1 W12 Press Push Button R, until the number 2 is displayed under the function indicator 'T’. The setting te, is the time to trip at 6 x Ig (or 6 x FLC) for the cold or starting condition and is adjustable with the appropriate potentiometer over a range of 5.0 to 60.0 seconds. The basic It inverse current/time curve can therefore be set to match the majority of motor thermal withstand curves. The hot or running curve corresponds to approximately 50% of the cold or starting curve. Furthermore, there is an additional facility to provide locked rotor and stalling protection as the trip times can be reduced to 75% or 50% of the basic thermal curve above 2 x lo (2 x FLC) but only when an auxiliary power supply is connected to terminals 10 and 11 It should be appreciated that the hot (running) curve is based on a prior loading of full load and the cold (starting) curve assumes a prior load of zero. The heating time constant of the relay is equal to: (setting ts, x 32) seconds. The cooling time constant is equal to twice the heating constant. POTENTIOMETER SETTING >/Iy Press Push Button R, until the number 3 is displayed under the function indicator ‘T’. The high set instantaneous short circuit protection if selected and not inhibited) is adjustable with the appropriate potentiometer over the range 2.0 to 12.0 x ly. This setting is doubled during motor start-up conditions enabling short circuit current settings lower than the motor starting current to. be used POTENTIOMETER SETTING lo/Iy Press Push Button R; until the number 4 is displayed under the function indicator ‘T’. The zero sequence or earth fault setting is adjustable over the range 0.06 10 0.6 x In, NOTE: If the earth fault unit is energised from the residual circuit connection of the three line CT's and if a sensitive earth fault setting is required, it may be necessary to use a series connected stabilising resistor to increase the burden of the CT’s to avoid spurious tripping due to CT mis-match and transient conditions during motor start-up. SG1 SWITCHGROUP CHECKSUM Press Push Button R, until the number 5 is displayed under the indicator T’ The number shown in the digital readout is the SG1 switchgroup checksum and is based on binary numbers 1 to 128 for each switch position 1 to 8. BINARY SG1 NUMBERS EXAMPLE s1 1 s2 2 If all switches were in position s3 4 ‘0'a figure 000 is displayed s4 8 with $1, $3, S5 and S6 in S5 16 position ‘1’ the number 53 $6 32 is displayed. s7 64 s8 128Pick up current = 1.05 x Io 100 x $ 9 = = G ® 1 10 R 8 3 2 w 2 = 9 é 1.0 = ® 3 04 itt 1 2 3 45 6 xt Pick up current = 1.05 x ly t 100 3 Q z E a 10) a a a w 2 = Q iz B10 & o 2 6 01 1 2 3 4.5 6 xl THERMAL CURRENT/TIME CURVES14 TECHNICAL SPECIFICATION Phase-current energizing inputs, terminals Rated current ly Thermal withstand capability —continuously —for 10s —for 1s Dynamic current withstand, half-wave Input impedance, independent of relay settings Rated frequency, standard relay Rated frequency, on request Earth-fault energizing inputs, terminals Rated current |, Thermal withstand capability —continuously —for 10s for 1s Dynamic current withstand, half-wave Input impedance, independent of relay settings Rated frequency, standard relay Rated frequency, on request Thermal overload and stall protection unit Rated load current lg for the protected object Setting accuracy of the load current Ip within the range 0.9... 1.1 xIy Setting accuracy of the load current Ip within whole range 0.40... 1.25 x ly Repeatability Setting of time to. Setting accuracy of time tox Value of stall time used by the stall protection ($4) Thermal prewarning level ©, in % of the thermal trip level ©, Cooling time-constant at zero input energizing current High-set overcurrent unit High-set current >setting Accuracy of high-set current setting within specified setting range Repeatability of set current Transient overreach at instantaneous operation Drop-off/pick-up ratio Operating time t>> Drop-off time Phase unbalance unit (N.p.s.) Fully stabilised to the maximum phase current standard pre-set sensitivity Special pre-set sensitivity for soft start applications Time lag at 15% unbalance Time lag at 30% unbalance Time tag at full unbalance i.e. when single phasing ‘or with incorrect phase sequence Drop off time 1-27-8 1-37-9 5A 1A 15A 3A 1004, 30A 300A 100A 10008 250A <20mn <100mn 50 Hz 60 Hz 25-26 25-27 5A 1A 15A 3A 100A 30A 500A 1004 10008 250A <20mn. <100ma2. 50 Hz 60 Hz 0.40... 1.25 xIy +1% +5% 21% 5...60 s +05s 50% or 75% of tex 95% 2 x heating te. 0.12% In 15% £2% 25% 0.95 50 ms (Nominal) <60 ms 15% 30% standard 20s, special infinite standard 5s, special 20s standard 1.5s, special 3.0s 1.08Undercurrent protection unit Operating value in percent of rated load current lo Operation time-lag Drop-off time Blocked below 12% of Ip Earth-fault unit Zero-sequence current setting lo Operation time-lag Accuracy of current setting within specified setting range Repeatability of set current Drop-off/pick-up ratio Drop-off time Auxiliary power supply ‘Supply voltage, any level 15 10s 1s 0.06... 0.6 x Iy 50 ms (Nominal) or 1, 15% 12% 0.95 <60 ms 80... 265 Va.c. or d.c. (standard) 18-80 V dc. (on request) Permitted ripple on supply voltage as per IEC 255-11 «12% Influence of the supply voltage on the operating values of the relay within the specified operative range <0.5% Output contact ratings Terminals 65-66 64.66, 67-69-68 70-72-71 Rated voltage, make and break 450 Vac. 250 Vac. 250 V de. 250Vde. Make and carry for 0.5 s 30a 108 Carry continuously 108 5A Breaking capacity for d.c., when the control circuit time-constant L/R.40 ms, at 48/110/220 Vdc. 7A/3A/1A 1.A/0.25 A/0.15A Contact material Agcd0, AgCd0, Test voltages Dielectric test voltage inputs and outputs between themselves and to the relay frame as per IEC 255-5, Series C Impulse test voltage, inputs and outputs between themselves and to the relay frame as per IEC 255-5 High frequency disturbance test voltage, inputs and outputs between themselves and to the relay frame as per IEC 255-6, Appendix C, class Ill Spark interference test voltage, inputs and outputs between themselves and to the relay frame as per SEN 36 15 03, class 3 Environmental conditions Specified service ambient temperature ‘Temperature influence on the operating values of the relay over the specified service ambient temperature range ‘Transport and storage temperature Long term damp heat withstand according to EC 68.2-3 Degree of protection of the relay cases Mass of the relay unit 2 kV, 50 Hz, 1 min KV, 1.2/50ys, 0.5 2.5 kV, IMHz 4. BRV “10... +55°C <0.2%/°C. -40... 70°C <95% at 40°C for 56 days IP 54 3.5kg16 Current Transformer Requirements Rated Current ly 5A 1A Burden 1.0VA O2VA Accuracy/Class 10P10 Ratio To give an output secondary current within the range 0.40... 1.25 x Iy TESTING The ability of a protective relay to properly perform its task is best verified by testing the relay at certain intervals. If not otherwise prescribed by local authority regulations or by the general practice of the company, it is recommended that the relays are tested every third year. Relays operating under abnormal environmental conditions should be tested every year or a visual check of the relay included in the maintenance programme of the installation. Rapid Relay Test A rapid relay test can be carried out with the relay in normal protective service. The rapid relay test consists of a check of the settings through push button R, and a check of the incoming current values through push button R Before this test is carried out, the relay is reset by depressing push buttons R, and R, together to erase all memorized relay data. This rapid test verifies the relay settings and proves that the complete energizing and measuring circuits of the protection unit are operating correctly. This test also checks the main current transformers, the secondary circuits as well as the relay matching transformers and measuring functions. Integrated Hardware Test The motor protection relay is provided with an integrated hardware test facility which is used for factory calibration of the relay. This facility can also be used for relay testing and is performed using a current injection set. The hardware test programme also includes an operational test of the output relay which provides a means for testing the trip circuits of the motor switching device. The alarm and signalling functions can be tested in the same way The hardware test is carried out by turning the selector switch $8 of the programme switch SG1 on the relay front plate to position ‘1’ When the relay auxiliary supply voltage is connected, the output relay B (terminals 71-72) operates, indicating an alarm condition. The alarm persists as long as the unit is in the hardware test mode. The test position is also indicated by the display, which shows a flashing 8888 readout. The flashing readout 8888 is actually a display test for checking the segments and the decimal points of the display. By depressing the push buttons R, and R, simultaneously ten different test positions can be successfully called up. The address digit shows the test position called up. By depressing both buttons continuously a fast scan can be made to the desired test position.Test Test 17 Position Current — Function obtained 1 1.00 x1y The current |,; as a multiple of the relay rated current |, displayed to two decimal points. NN 2. 1.00 xIy The current 13 as a multiple of the relay rated current ly. displayed to two decimal points. 8 0.50 xy The earth-fault current Ip as a multiple of the relay rated current ly to three decimal points. 4. 10.0x1y The current I,; or ly as. a multiple of the relay rated current Ix, displayed with one decimal point. 5. 1.00 xl, The negative phase sequence current filter should see a full unbalance condition of between 55% and 59% when the test current is fed to the input of phase LI or L3 6. — Checksum of the programme selector switch SG1 With all switches in the position ‘0’ a figure 000 is displayed and with all switches in the position ‘1’ a figure 255 is displayed. For a complete testing alter the position of one switch at a time and verify an alteration of the checksum 7 - Test of the stall protection unit. When no voltage is, fed to the stall control input terminals 10 and 11 the display shows a running decimal point. When a voltage is fed to input terminals 10 and 11 the display shows three decimal points flashing simultaneously. 8. a Output relay test. The output relays operate at 2.0 second intervals in the following sequence:- a) Relay A and B reset—fault alarm, no trip. b) Relay B picks up—no fault alarm, no trip. c) Relay A picks up—no fault alarm, trip, The timing of this sequence can be used for checking the relay time base and is best carried out by noting the time span for 100 relay operations. 9. _ Internal voltage test. In this test position two internal test voltages are displayed, one directly and the other by depressing button R>. These voltages are used by the self-supervision system. The values should be within the range 2.30... 2.70. 0. - This test position is used for factory testing only. In this position a figure 2 is displayed Switching the hardware test programme to normal relay protective functions always goes over the display test position. Even if switch S8 has been returned to its normal position (‘0’), the relay will remain in its test mode until the whole test programme has been scanned through Note: Switching from the test mode to normal relay protective function always brings about a complete relay reset, i.e. all memorized data are erased. After a reset the programme memory checksum test is automatically performed, before the relay is returned to service, see ‘Self Supervision Functions’18 SECONDARY INJECTION TESTING Earth Fault Check Connect injection set to terminals 25 and 27 for 1 amp input or terminals 25 and 26 for 5 amp input. Slowly increase the injected current until the relay trips. Check that a figure 1 is shown on the display, indicating an earth fault trip. Press R, and go to memorised value No. 3 to check at what value the earth fault element tripped. High Set Overcurrent Check SG1 No. 1 is switched to position C.B. (0) SG1 No. 5 is switched OFF (0) Link terminal 3 and 9 together for 1 amp input or terminals 2 and 8 for 5 amp input and connect the injection set to terminals 1 and 7. Slowly increase the current until the relay trips. Check that a figure 2 is shown on the display, indicating a high set overcurrent trip. Depress R, and check the value of injection current at which the relay tripped. Phase Unbalance Check SG1 No. 5 is switched OFF (0) Connect injection set to terminals 1 and 7 and link as above. Inject 1 x ly through the relay. Depress R, and select reading No. 4. Check that the percentage negative phase sequence current is reading between 55% and 59%. Turn current off. SG1 No. 5 is switched ON (1) Inject 1 x ly once again and check the relay trips on unbalance, figure 3 will be displayed Thermal Curve Check SG1 No. 1 is switched to position CONT. (1) SG1 No. 5 is switched OFF (0) A single phase injection test requires the phase inputs to the relay to be connected in phase opposition, i.e. when the 1 amp inputs are selected, current from the injection set is fed to terminals 1 and 7 and terminals 3 and 9 are linked together, when the 5 amp inputs are selected terminals 2 and 8 are linked together and the injection set connected to terminals 1 and 7. Set potentiometer setting tg, to 5 seconds. Adjust current to 6 x Ip then turn current OFF. Switch the auxiliary voltage to the relay OFF, depress both push buttons R, and R, together, keeping them depressed switch the auxiliary supply back ON. This procedure completely resets the memory. Depress R, and check reading No. 7 is set at zero. Inject the pre-set current 6 x I, and time the relay to trip. Time to trip working on the cold curve is § seconds +0.7 secondsMAINTENANCE AND REPAIRS 19 The relay does not include any parts or components which are subject to abnormal mechanical or electrical wear under normal operating conditions Therefore provided the relay is operating within the conditions as stated in the technical specification, the relay is practically maintenance free If the environmental conditions differ from those specified, the relay should be visually inspected on a regular basis or in conjunction with secondary current injection testing. When a visual inspection is carried out, the following should be noted:- — check for signs of mechanical damage to the relay and main printed circuit boards in the relay — any accumulation of dust in the relay case should be removed by careful blowing — check all components for signs of oxidisation and verdigris on the copper foil of the printed circuit boards — check contact plugs for signs of tarnish In the unlikely event of the relay failing in operation or if the operating values differ from those stated, the relay should be returned to the manufacturer for inspection and repair The user can carry out minor repairs by replacing faulty printed circuit boards and a list of spares are given below which can be obtained for this purpose:- PBCJ 5A1 Measuring Unit PBA-ZU 240 80... 265 V AC/DC Power Supply Unit PBTR 3A1 Output Relay Module The user should not attempt to carry out any repairs to the electronic circuits other than to replace a complete printed circuit board. Note Static protective relays are measuring instruments and should be handled with care and protected against moisture and mechanical stress, especially during transport.