PPMV Coral Springs, FL Do You Remember Electromechanical Relays?

ABB Inc- 1 - Value Creation 9/17/2008

FT Switches and EM Relays

FT Switch Product Evolution

The Westinghouse Flexitest (FT) case was developed over 50 years ago to provide safe, reliable, in-case test capability for electromechanical relays FT switch assemblies in the case provide a reliable means to insert or remove the internal relay assembly, providing secure circuit isolation Individual blades may be opened to securely isolate trip circuits and safely short CT circuits The relay may be removed from the case for bench testing, or remain in the case for testing with separate source, in service or current probe test plugs

FT Switch Product Evolution

The flexibility provided by the FT case design evolved into a separate family of molded base test switches that provide a costeffective means for isolation and testing of relays, meters and other electrical devices, and particularly for safely opening a current circuit in the proper sequence. Standard switches are available in many combinations of potential, current or current shorting poles and special combinations are available on request

Standard FT-1 10 pole Switch

FT-14, 14 pole Switch

FT-1 with clear cover and colored handles

FT-1X and FT-14X Switch Configurations

Extended rear terminal 10 or 14 pole FT-1 Rear terminals of the switch are at the same depth as most 19 rack mounted relays Rated for 600 volts at 30 amps. Only 2U rack unit space required Available in any variety of rack unit height Customized paint, plating or material available Allows equipment to be mounted directly above and below unit Option of 8.25, 10.25 or 12.25 inch depths Other features same as standard FT-1 switches
14 pole Extended FT Switch 10 pole Extended FT Switch

FT-19R
The FT-19R assemblies can accommodate up to three FT-1 switches mounted on a 19 wide, 2 Rack Unit (2RU), 3RU, or 4RU steel or brushed aluminum mounting plate. Plate height, color, and switch configuration can be customized to users requirements. The Full Length Black, Individual Clear, and Individual Black covers are optional. All covers can be meter sealed. Standard FT Plug for all testing requirements Descriptive Bulletin 41-078
Brushed Aluminum flat panel Grey rolled steel panel 2U

Beige rolled steel panel 2U

Grey rolled steel panel 3U with labels

Black rolled steel panel 3U, switches located at the bottom

FT-1F, Front Connected FT Switch

Front Connected FT Switches have the smallest foot-print of ant 10 pole design in the market
Ideal for mounting inside panels, may be mounted to panel on Unistrut or DIN rails Either black or clear covers may be specified Any configuration that is available from a regular 10 pole FT switch may be specified Any available color switch handle may be specified

Descriptive Bulletin 41-079

FT-1 Web Based Configurator Tool

FT-1 Applications Bus Differential Configuration

FT-1 Configuration C-C C-C C-C C-C-C-A

IA IB IC IN

FT-1 Web Based Configurator Tool

FT-1 Web Based Configurator Tool

Aging Nuclear Power Plants

About 30 percent of our nations nuclear power plants have had equipment failures partly do to equipment having aged There are 103 nuclear power plants in the United States Nuclear power plants supply about 20 percent of our electricity Average life span is about 40 years Approximately 60 percent of the nuclear power plants in the US are greater than 20 years old The problem is getting worse as the equipment gets older If the equipment is not upgraded, eventually failures will adversely affect plant safety and performance

Upgrading Relays with Sensors

One of the big reasons people upgrade their EM substations to microprocessor relays is to gain communications to the relays and data acquisition. Cost to upgrade is large and includes:
Extensive engineering time Cost of new relays All new panels Complete rewiring of substation Real Estate may be limited

SE Intelligent Data Sensors eight channel receiver and Clamp- on Sensor

Testing Relays with Sensors

Upgrading Relays with Sensors

Upgrading Relays with Sensors

Actual Labor Cost Model

Quantity Item 1 Wiring Inside of Panel 4 conductor, #8 Cable for 2 Voltage & Currents 12 Conductor Control 2 Cable Labor for Terminations C and Pulling Table 200 Hrs and Pulling Cable Cost $8,000 $1.95/ft/cable $2.50/ft each $125/hr

This does not include costs such as Asbestos and PCB removal Total cost can exceed $30,000

A New Attractive Low Cost Alternative

Clamp on Sensors to automate Electro-Mechanical substations Small clamp on sensors provides an analog output of 0 to 5V which is proportional to the current flow through the wire. Features include:
Clamp-on AC/DC Sensor Sensitive down to 10 microsecond resolutions Single cable for Power & Output Shielded Enclosure Fits 12 AWG electric Wires 5% accuracy range

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2nd Harmonics under 12% for 2 cycles (minimum seen is 6%) Plus, the magnitude is over 2 Amps RMS (enough to operate the diff relay)

ABB Inc- 23 - Value Creation 9/17/2008

Coral Springs, FL

The Benefits of ABB Electromechanical Relays

By: Glenn Goldfarb

EM
ABB Inc- 24 - Value Creation 9/17/2008

The Benefits of Electromechanical Relays

EM Relays are still the backbone of present day power systems and can be used for backup protection even in new installations

The Benefits of Electromechanical Relays

The Silent Sentinel

Selectivity The Electromechanical Relay is a Single Function Relay and originally know as the Silent Sentinel - It only responds for a fault condition.

The Benefits of Electromechanical Relays

Reliability Electromechanical Relays are not susceptible to Fast Transients, Oscillatory SWC, EMI, RFI, Impulse or any other noise induced in the power system.

The Benefits of Electromechanical Relays

Security Electromechanical Relays are not susceptible to terrorists or computer hackers. No Password Needed!

The Benefits of Electromechanical Relays

Simplicity Electromechanical Relays do not require Firmware or Software upgrades!

The Benefits of Electromechanical Relays

Minimal Documentation No red tape or stacks of paperwork and drawings required to change relay types

The Benefits of Electromechanical Relays Speed EM Relays Trip in to 1 cycles relays operate for the fault parameters Microprocessor Relays Trip in 1 to 2 cycles - relays have to process fault parameters and make a decision before operating

The Benefits of Electromechanical Relays

You can See and Hear Electromechanical Relays Operate Cylinder and Polar Unit Contacts Close / Open Induction Disk Elements move clockwise and counterclockwise

The Benefits of Electromechanical Relays

No more burned modules

EM Relays do not have power supply modules to burn up!

Presented By: Glenn Goldfarb

CO, CO (HI-LO)

ABB Inc- 34 - Value Creation 9/17/2008

CO (HI-LO) Overcurrent Relay

The CO Relay is a single phase non-directional time overcurrent device. It is used to sense current level above the setting and normally is used to trip a circuit breaker to clear faults. A wide range of characteristics permit applications involving coordination with fuses, reclosers, cold load pickup, motor starting, or essentially fixed time applications.
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Induction Unit
Need minimum current level to operate (pickup-value) Inverse time characteristics (more current = less time to operate)

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Electromagnet
Torque developed in disc is derived from interaction of fluxes by the electromagnet with those from induced currents in the aluminum disc.
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Lag Coil

IF lag coil is open no torque is developed in disc.

Induction Disc
T=12 SIN(2-1) Disk is aluminum Eddy currents are generated on the disc due to the magnetic flux from the electromagnet

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Spiral Spring

Spring conducts current to the moving contact Adjusting the spring tension will change the minimum pickup value

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Disc
The shape of the disc, together with the spiral spring and the electromagnet design, provides a constant minimum operating current over the travel range. The weight is to balance the disc.

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Electromagnet

Lag Coil

Time Characteristics
The main factor to determine the time characteristics of the induction unit is the type of laminations used. The permanent magnet will serve to adjust the operating time of the induction unit by dampening the disc (fine adjustment).
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Magnetic plugs in the electromagnet control the degree of saturation (curve shape).

CO Electromagnet Laminations
Different types of laminations are used to obtain the curve characteristics. Laminations that saturate faster will create a slower relay. CO-2 & CO-11 are the fastest and CO-5 & CO-7 are the slower.

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CO Typical Time Curve

ICS (Indicating Contactor Switch)

Three main functions Provide indication of the relay operation. Provide a path for high tripping currents.
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(Relay contacts normally not designed to carry heavy currents). Provide a seal in action.

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ICS Unit

IIT(Indicating Instantaneous Trip)

Very similar to ICS unit. Designed to operate under AC current. Operates as an instantaneous overcurrent trip unit. Adjustable core provides pickup adjustment.

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IIT Unit

Equipped with a Lag Loop to smooth the force variations due to the
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alternating current input.

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CO Internal Schematic

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CO External Schematic

Acceptance Test
Minimum Trip: With the time dial set at 6, apply tap value current plus 3%, the contact should leave the back stop. Then lower the current to minus 3% of the tap value and contact should return to the back stop. Operating time (with time dial at 6)
CUST. S E T T IN G S T im e C u rv es S ee C u rv e 619584 418245 418246 418247 418248 418249 Sub 2 288B 655

R ela y T y p e
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H I-L O H I-L O H I-L O H I-L O H I-L O H I-L O H I-L O

CO2 CO5 CO6 CO7 CO8 CO9 C O 11

TEST A Ia c X T im e Tap (sec.) V a lu e 3 .5 5 3 - .58 7 2 3 6 .2 9 3 9 .3 1 2 2 .3 7 4 2 .54 6 2 4 .1 4 4 .4 0 2 1 3 .0 8 1 3 .6 2 2 8 .6 9 9 .0 5 2 1 0 .7 1 1 1 .8 3

Ia c X T ap V a lu e 20 10 20 20 20 20 20

TEST B T im e (sec.) .2 1 1 - .22 9 * * * 1 3 .7 3 1 4 .8 7 1 .1 4 8 1 .23 2 1 .0 8 1 .1 4 1 .0 9 1 .1 3 .6 3 5 - .66 5 .2 2 9 - .25 5 * *

TEST C Ia c X T im e Tap (sec.) V a lu e 1 .3 4 9 .4 5 7 .6

**FOR 50 HZ RELAY USE .228 - .288 ***FOR 50 HZ RELAY USE .22 - .262

Technical Information
IIT UNITS
Contacts close with current suddenly applied Sec. 4. A Tap Setting Pickup Amps * Sec. 4. C Tap Setting Pickup Amps * Sec. 4. D Tap Setting Pickup Amps *

Range

2 - 48

2- 7

1.7 - 1.9

7 - 17

17 - 48

17

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3 - 48

3- 9

2.7 - 2.9

9 - 20

20 - 48

17

6 -144

6 - 20

5.1 - 5.7

20 - 50

20

50 - 144

50

The IIT units are calibrated between 85% and 95% of lower tap. Example 2 48 amps unit is adjusted between 1.7 and 1.9 amps. The IIT can be adjusted to any pickup within the range with just changing the tap screw and adjusting the core screw to the desired level.

Technical Information
ICS UNITS The most common settings for the ICS unit are 0.2 & 2.0 DC amps. To verify the pick-up, close the contact of the timing unit (CO unit) and apply the tap current to the proper terminals according with the internal schematic. The most common connection is terminals 10 and 1.

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CO Relay characteristics & Specifications

Time Overcurrent Unit General: Frequency: Minimum Trip Current: Operating Time:
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Non-Directional, Single Phase 60 HZ +/- 3 % Tap Value Curve dependent 2200 VAC for one second

(seven CO types available) Dielectric Strength: between all circuits and each circuit to the case with leakage current not exceeding 1 milliampere Option: Torque control

ITH Relay Characteristics & Specifications

High Drop-out Instantaneous (ITH) Unit (Optional) General: AC operated and adjustable core screw Drop-out to pick-up ratio of 90% over entire 2 to 1 pick-up range Operating range can be increased to a 4 to
ABB Inc - 55 - FT Products-Value Presentation

1 ratio Operating Time:At 200% of trip setting At 500% of trip setting < one cycle one-half cycle

At 1000% of trip setting one-quarter cycle

Presented By: Glenn Goldfarb

KD-10 and KD-11 Compensator Distance Relay

ABB Inc- 56 - Value Creation 9/17/2008

KD-10 and KD-11 Compensator Distance Relay

The type KD-10 relay is a polyphase compensator type relay which provides a single zone of phase protection for all three phases. It provides essentially instantaneous tripping for phase-to-phase faults, twophase-to-ground faults, and three-phase faults within the reach setting and sensitivity level of the relay. The type KD-11 relay, is similar to the KD-10 relay except that the characteristic impedance circle for the 3-phase unit includes the origin. This relay is usually applied as a carrier start relay in directional comparison blocking schemes but it may also be used for time delay tripping in non pilot distance relaying.

KD Relay
Application: Compensator distance relay that provides a single zone of phase protection for all three phases. It provides tripping for phase to phase, two phase to ground and three phase faults within the reach setting and sensitivity level of the relay

KD Relay Construction
Cylinder Unit: Main function is to operate when the angle between two signal applied is within certain range. Widely used as a directional unit and in impedance relays.

KD Relay Construction
Cylinder Unit: T=KI1I2SIN(1-2)-KS Where K and are design constants. Different combinations of input quantities can be used for different applications, system voltages or currents or network voltages.

KD Relay Construction
Compensator: Designated as T Current to Voltage air gap transformer. Voltage side has a tap which divides the winding in two sections. The output voltage angle can be changed by connecting a resistor across one of the voltage winding sections.

KD Relay Construction
Compensator:

Phase-to-Phase Fault
T - Connection Vf = Desired Fault Voltage Va = Vf Vb = Vf 0 180 1-2-3
V1-2 = V3-1 = V2-3 = 120V

Vc = 3/2(120) or Vc = 104V 90 lead = 270 lag

104v

25v

25v = 50v

3 Phase Fault

KD Relay 3 Phase Voltage Input

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KD Relay
Operation:

KD Relay
Impedance Circle

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KD Relay External Schematic

KD Relay Equations needed for testing

ST 1 M

Z Setting

Relay Setting

Impedance measured by 3 phase unit

VL L Zr = 3 IL
IL = VL L 3Z Setting
Used to find required test current

Impedance measured by 2 phase unit

V Zr = L L 2 IL
IL = VL L 2 Z Setting
Used to find required test current

Tests Connections

Basic Test Connections for Type KD-10 and KD-11 Relays

Settings Calculation
Relay reach is set on the tap plate. The tap markings are: T, TA, TB, and TC (Short reach) 0.23, 0.307, 0.383, 0.537, 0.690, 0.920, 1.23 (Med. Reach) 0.87, 1.16, 1.45, 20.03, 2.9, 40.06, 5.8 (Long reach) 1.5, 2.0, 2.5, 3.51, 5.0, 7.02, 10.0 S1, SA, and SC (Values between taps) 1, 2, 3 M, MA, MC .0, .03, .09, .06 Calculations for setting the KD-10 and KD-11 relays are straightforward and apply familiar principles. Assume a desired balance point which is 90 percent

Settings Calculation
Of the total length of line. The general formula for setting the ohms reach of the relay is: Rc Z = 0.9 Zpri ___ RV The terms used in this formula and hereafter are defined as follows: Z 0.9 Zpri = The desired ohmic reach of the relay in secondary ohms. = The portion of the total line for which the relay is set. = Ohms per phase of the total line section [Equ. 9]

RC, RV = Current and Voltage transformer ratio

Settings Calculation
The relay tap plate setting, Z, is set according to the following equation: Z = ST 1M T S +M = Compensator tap setting. = Auto-transformer primary tap setting. = Auto-transformer secondary tap setting. (This is a per unit value and is determined by the sum of the values between the L and the R leads. The sign is positive when L is above R and acts to lower the Z setting. The sign is negative when R is above L and acts to raise the Z setting.) [Equ. 10]

Settings Calculation
Example 1 Step 1 Assume the desired reach, Z is 7.8 ohms at 75. Step 2a In Table II we find nearest value to 7.8 ohms 7.88 that is 100 x 7.88 = 101 percent of the desired reach. 7.8 Step 2b From Table II read off: S T M = = = 2 4.06 +.03

Settings Calculation
Example 1 (Cont.) and L lead should be connected over R lead, with L lead connected to .03 tap and R lead to tap 0. Step 2c Recheck settings. ST 1M 2 x 4.06 1 + .03

Z=

= 7.88

Settings Calculation

KD Relay Characteristics & Specifications

General: Frequency: Ranges: Compensator Distance 60 HZ (50 HZ available as Similar To 60HZ) .2 4.5, .75 21.2, and 1.3 36.6 Ohms

Current Circuit Rating:10 A. continuous except for the 1.3 36.6 ohm range where for S = 1, T = 10 S = 2, T = 10 S = 3, T = 10 240 A. / 1 sec. Operating Speed: Phase-to-Phase Unit current times compensator setting dependent (ref. curves) 6 A. continuous 8 A. continuous 9 A. continuous

S = 1, T = 7.02 7 A. continuous

KD Relay Characteristics & Specifications

Dielectric Strength: 2200 VAC for one second between all circuits and each circuit to the case with leakage current not exceeding three milliamperes

Indicating Contactor Switch (ICS) General: Range: Coil Resistance: Contact Rating: DC operated and suitable for DC control voltages up to and including 250V. 0.2 / 2.0 amps (tapped coil) 0.2 amp tap 6.5 ohms 2.0 amp tap 0.15 ohm 30 amperes at 250 volts dc and carry long enough to trip a circuit breaker