Service Manual Type MCAG 14, 34 High Stability Circulating Current Relays
Service Manual Type MCAG 14, 34 High Stability Circulating Current Relays
Service Manual Type MCAG 14, 34 High Stability Circulating Current Relays
CONTENTS
SAFETY SECTION 5
1. INSTALLATION 9
2. COMMISSIONING 10
2.1 Description of relay 10
2.2 Calculation of relay setting 11
2.3 External Metrosils 11
2.4 Commissioning preliminaries 11
2.5 Commissioning tests 13
3. MAINTENANCE 14
4. MECHANICAL SETTINGS 15
4.1 General 15
4.2 Contact settings 15
4.3 Mechanical flag settings 15
5. PROBLEM ANALYSIS 15
5.1 Failure to operate 15
5.2 Excessive current taken by relay 16
5.3 Output contacts not changing state 16
6. SPARES 16
7. COMMISSIONING TEST RECORD 21
REPAIR FORM 23
4
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.
*Note: The term earth used throughout the product documentation is the direct
equivalent of the North American term ground.
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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)
6
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.
Decommissioning: The auxiliary supply circuit in the relay may include capacitors
across the supply or to earth. To avoid electric shock or energy
hazards, after completely isolating the supplies to the relay
(both poles of any dc supply), the capacitors should be safely
discharged via the external terminals prior to decommissioning.
Disposal: It is recommended that incineration and disposal to water
courses is avoided. The product should be disposed of in a safe
manner. Any products containing batteries should have them
removed before disposal, taking precautions to avoid short
circuits. Particular regulations within the country of operation,
may apply to the disposal of lithium batteries.
7
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.
8
Section 1. INSTALLATION
1.1 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
possiblity of premature failure is eliminated and a high degree of performance can
be expected.
1.2 The relays are either despatched individually or as part of a panel/rack mounting
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 the nearest
ALSTOM T&D Protection & Control representative should be promptly notified.
Relays which are supplied unmounted and not intended for immediate installation
should be returned to their protective polythene bags.
1.3 Care must be taken when unpacking and installing the relays so that none of the
parts are damaged or their settings altered and must at all times be handled by
skilled persons only.
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.
1.4 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. The action of the de-
humidifier crystals will be impaired if the bag has been exposed to damp 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 –25°C to +70°C.
1.5 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
R6008.
Publication R7012 is a Parts Catalogue and Assembly Instructions. This document 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
relays.
Publication R6014 is a list of recommended suppliers for the pre-insulated
connectors.
9
Section 2. COMMISSIONING
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2.2 Calculation of relay setting
The minimum setting voltage to ensure stability is:
IF
VS ≥ (RCT + 2RL)
N
The minimum knee point voltage (VK) of the CT must be:
VK ≥ 2VS
The relay is current calibrated and has settings chosen from the range given in 2.1.1.
It has a burden of approximately 1VA at setting.
Having calculated VS a suitable relay tap must be chosen to give the required
primary operating current IP.
IP = N (IR + nIE)
When the value of IR has been selected the value of stabilising resistor RST must be
calculated.
VS VA
RST = –
IR IR2
2.3 External Metrosils
When the maximum voltage which appears across the relay circuit on internal faults
exceeds 3000 volts peak a metrosil non-linear resistor must be fitted across the relay
and the stabilizing resistor.
The peak voltage can be calculated from the formula:
11
Note that 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
test block (coloured orange) and with terminals allocated odd numbers (1, 3, 5, 7,
etc.).
2.4.2 Earthing
Ensure that the case earthing connection above the rear terminal block, is used to
connect the relay to a local earth bar.
2.4.3 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. Deliberate circuit earthing links, removed for the tests, subsequently must be
replaced.
2.4.4 Terminal allocation
Terminals of the relay are normally allocated as below, but reference should always
be made to the relevant diagram.
a) Single pole relays
Normally open contacts 1, 3 and 2, 4.
AC current input – 27, 28.
b) Triple pole relays
Normally open contacts 1, 3 and 2, 4.
The contacts are normally connected in parallel for the three phases but a version
of the relay having contacts brought out separately is available.
AC current inputs – 23, 24 : 25, 26 : 27, 28.
2.4.5 Instructions to ensure that the relay can be commissioned at the specific settings for
the application.
It is only necessary to check the relay at the setting on which it is to be used.
The relay must not be used at any setting other than that for which the setting has
been calculated.
2.4.6 Test equipment required
1 – Secondary injection test equipment capable of providing an ac voltage supply of
up to at least 120% of the relay setting.
1 – Multifinger test plug type MMLB 01 for use with test block type MMLG
if fitted.
1 – Miniature split plug type MMLB 03 to fit relay plug bridge.
3 – Calibrated multimeters 0 – 10A ac, 0 – 400V ac
1 – Set primary injection testing equipment.
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2.5 Commissioning tests
If the relay is wired through an MMLG test block it is recommended that all
secondary injection tests should be carried out using this block.
Ensure that the main system current transformers are shorted before isolating the relay
from the current transformers in preparation for secondary injection tests.
DANGER
DO NOT OPEN CIRCUIT THE SECONDARY CIRCUIT OF A CURRENT
TRANSFORMER SINCE THE HIGH VOLTAGE PRODUCED MAY BE LETHAL AND
COULD DAMAGE INSULATION.
When type MMLG test block facilities are installed, it is important that the sockets in
the type MMLB 01 test plug, which correspond to the current transformer 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.
It is assumed that the initial preliminary checks have been carried out.
2.5.1 Relay CT shorting switches
With the relay removed from its case, check electrically that the CT shorting switch is
closed.
2.5.2 Secondary injection testing
Connect the circuit as shown in Figure 1 and ensure that the current transformer
primary is open circuit and that if any earthing connections are fitted, they do not
short out the primaries of any current transformers.
Increase the current until the relay just operates.
Note the current in the relay (this can be done using the miniature split plug inserted
into the appropriate position of the plug bridge connected to an ammeter).
Note also the voltage (VR) at which the relay operates which should correspond to
the setting VR of the relay plus stabilising resistor, with a tolerance of +10%.
The total secondary current for operation will be given on ammeter A1. This test
should be repeated for each pole of the relay.
2.5.3 Primary injection testing
It is essential that primary injection testing is carried out to prove the correct polarity
of current transformers.
Before commencing any primary injection testing it is essential to ensure that the
circuit is dead, isolated from the remainder of the system and that only those earth
connections associated with the primary test equipment are in position.
2.5.4 Primary fault setting
The primary fault setting of any balanced scheme can be checked using the circuit
shown in Figure 2. The primary current is injected into each current transformer in
turn and increased until the relay operates. The voltage at which the relay operates
should be within +10% of the relay setting voltage VR. The primary current for
operation and relay current should be noted.
In the case of machine protection, similar tests must be carried out by injecting first
into each current transformer in turn to determine the primary fault setting.
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For large machines, the machine itself can be used to provide the fault current to
check the primary fault setting as shown in Figure 5. The machine should be run up
to speed with no excitation. The excitation should then be increased until the relays
have all operated.
The primary current, relay current and relay plus stabilising resistor voltage, should
be noted as each relay operates.
2.5.5 Through fault stability
With any form of unbalanced protection it is necessary to check that the current
transformers are correctly connected. For this purpose with a restricted earth fault
scheme the circuit shown in Figure 3 may be used. During this test it is necessary to
measure the spill current in the relay circuit and short out the relay and stabilising
resistor (if fitted). The current is increased up to as near full load as possible and the
spill current noted. The spill current should be very low, only a few milliamps if the
connections are correct. A high reading (twice the injected current, referred through
the current transformer ratio) indicates that one of the current transformers is reversed.
Injection should be carried out through each phase to neutral.
Where primary injection is not practicable in the case of restricted earth fault
protection on a transformer it may be possible to check stability by means of back
energising the transformer from a low voltage (415 volt) supply as shown in
Figure 4.
In the case of machine protection, similar stability tests must be carried out by
injecting into one and out of another current transformer connected on the same
phase.
For large machines, the machine itself can be used to provide the fault current, but
the short circuit must now be fitted as shown in Figure 6. The machine should be run
up to normal speed and the excitation increased until the primary current is
approximately full load, when the spill current should be checked.
All other types of balanced protection should be tested in a similar manner.
At the conclusion of the tests ensure that all connections are correctly restored and
any shorting connections removed.
Section 3. MAINTENANCE
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Section 4. MECHANICAL SETTINGS
4.1 General
Armature gap measurements should be made with the top of the feeler gauge level
with the centre line of the core.
Contact pressures are measured with a gramme gauge at the contact tips.
In general, contact gaps and follow through are defined by quoting an armature gap
at which the tips should be just closed or just open.
The relay contact state is always defined with the relay in the unenergised position,
unless otherwise specified on the appropriate circuit diagram.
4.1.1 With the armature closed the clearance between the back of the armature and the
back stop should be 0.003"/0.008".
4.1.2 Nominal armature gap open 0.050"/0.060" for all types.
4.2 Contact settings
4.2.1 Normal duty make contacts
With the armature closed onto a 0.011" feeler gauge the make contacts should be
closed, but should be open using a 0.013" feeler gauge.
Force to just close the make contacts 11/16 grammes.
4.3 Mechanical flag settings
4.3.1 Settings for self reset units
With the armature closed onto a 0.013" feeler gauge the flag should be free to fall,
but should not fall using a 0.018" feeler gauge. Adjustment is made to the catch
spring on the flag.
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5.2 Excessive current taken by relay
Transformer damaged
Incorrect frequency of supply – this is marked on the front of the module
Shorting switch not opening
5.3 Output contacts not changing state
Operating push rods not in position
Check output terminals with reference to diagram
Internal wiring damaged
Contamination of contacts
Contacts should be cleaned with the burnishing tool, supplied in relay tool kits.
On no account should knives, files or abrasive materials be used.
Check mechanical settings as per Section 4.
Section 6. SPARES
When ordering spares, quote the full relay model number and any component
reference numbers, or briefly describe the parts required.
Should the need arise for the equipment to be returned to ALSTOM T&D Protection &
Control Ltd 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.
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Relay
A2 Metrosil (if fitted)
Figure 1 Secondary injection of relay to check secondary operating current, setting voltage and
relay operating current
A1
Primary injection
test set
A2
Relay
17
A1
Primary injection
test set A
Temporary connection
A1
A
LV
B supply
A2
Relay
Stabilising resistor (if fitted)
Figure 4 Stability check on restricted earth fault scheme by back energising with a low voltage
supply
18
Temporary short circuit
Isolating
Generator
links
A
B
C
V 87 87 87
A
B
C
A2 A2 A2
87 87 87
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Section 7. COMMISSIONING TEST RECORD
High Stability Circulating Current Relay Type MCAG 14, 34 Date _______________
Test results
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2.5.5 Stability check by primary injection
Restricted earth fault
A–N
B–N
C–N
A1 – A2
B1 – B2
C1 – C2
Where more than two sets of current transformers are involved injection should be
carried out between set 1 and each other set in turn.
______________________________________ _______________________________________
Commissioning Engineer Customer Witness
______________________________________ _______________________________________
Date Date
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REPAIR FORM
Please complete this form and return it to ALSTOM T&D Protection & Control Limited with the
equipment to be repaired. This form may also be used in the case of application queries.
continued overleaf
23
✁
6. What did happen?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
______________________________________ _______________________________________
Signature Title
______________________________________ _______________________________________
Name (in capitals) Company name
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✁
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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: enquiries@pcs.alstom.co.uk Internet: www.gecalsthomgpc.co.uk