Types MCAG 19, 39

Protective Relays

Service Manual
R8035F

CONTENTS
1. 1.1 1.2 1.3 1.4 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3. 4. 4.1 4.2 4.3 5. 5.1 5.2 5.3 5.3.1 6. 7. INSTALLATION General Unpacking Storage Site COMMISSIONING General Electrostatic discharges Wiring Commissioning preliminaries Insulation Earthing Main current transformers Equipment required Electrical tests Output Contacts MAINTENANCE MECHANICAL SETTINGS General Contact setting Mechanical flag setting PROBLEM ANALYSIS Failure to operate Operating at the incorrect values Output contacts Output contacts not operating mechanically SPARES COMMISSIONING TEST RECORD REPAIR FORM 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 9 11

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Section 1.
1.1

INSTALLATION

General Protective relays, although generally of robust construction, require careful treatment prior to installation. By observing a few simple rules the possibility of premature failure is eliminated and a high degree of performance can be expected. 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 the 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 GEC ALSTHOM T&D Protection & Control promptly notified. Relays which are supplied unmounted and not intended for immediate installation should be returned to their protective polythene bags.

1.2

Unpacking Care must be taken when unpacking and installing the relays so that none of the parts are damaged or their setting altered, and must be handled by skilled persons at all times. 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 form their cases should not be left in situations where they are exposed to dust or damp. This is particularly applies to installations which are being carried out at the same time as construction work.

1.3

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. The action of the dehumidifier 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 placing it in the carton. Dust which collects on a carton may, on subsequent unpacking, find its way in to 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

1.4

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 R6035. 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.

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Publication R6001 is a leaflet on the modular integrated drawout system. Publication R6014 is a list recommended suppliers for the pre-insulated connectors.

Section 2.
2.1

COMMISSIONING

General Before leaving the factory all relays are accurately adjusted, tested and carefully packed. Hence there should be no need for any re-adjustment on commissioning. Moving parts are held in position during transit by rubber bands and packing. These should be removed carefully.

2.2

Electrostatic discharges The relay uses components which are sensitive to electrostatic discharges. When handling the module, care should be taken to avoid contact with components and electrical connections. When removed form the case for storage, the module should be placed in an electrically conducting anti-static bag.

2.3

Wiring Check that ratings of relay agree with the supplies to which it is to be connected. Check all wiring connections to the relay, including the case earthing connection above the terminal block. It is especially important that dc supplies and magnetic blowout contacts are wired with the correct polarity. The relay diagram number appears inside the case.

2.4

Commissioning preliminaries To gain access to the relay first loosen the captive cover screw and carefully remove the cover from the case. The module can then be removed from the case by grasping the handles at the top and bottom of the front plate and pulling forwards. Care must be taken to ensure that mechanical settings of the element are not disturbed. Carefully remove the rubber band securing the flag mechanism Check that the bottom end of the contact operating card has not been dislodged from the slot in the armature extension and that the ends of the push rods are located in the holes in the contact springs. Carefully actuate the armature of each unit in turn with small screwdriver/probe. Note immediately after the point where any make contacts just close there is a further small movement of the armature. This ensures that contact follow through and wiping action is present. Repeat similarly with break contacts on armature release. On units fitted with hand reset flag indicators, check that the flag is free to fall before, or just as, any make contacts close. Replace the module in the case and refit the cover. Make sure that the reset mechanism in the cover is correctly located with respect to the relay element, and that the flag(or mechanism) can be reset.

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2.5

Insulation The relay and its associated wiring, may be insulation tested between: a) all electrically isolated circuits b) 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. Disconnect the external wiring from the appropriate case terminals to low application of the test supply. Consult the appropriate application diagram for the case terminals FIMCAG11 001 FIMCAG31 001 for MCAG19/39 relays

The relay ratings and settings are indicated on the front of each module. 2.6 2.7 Earthing Ensure that the case earthing screw is used to connect the relay to a local earth. Main current transformers Do not open the secondary circuit of a live ct, since the high voltage produced may be lethal to personnel and could damage insulation. 2.8 Equipment required A current source capable of supplying sinusoidal current at the appropriate test current levels. An ammeter with the appropriate current range. 2.9 Electrical tests Set the plug bridge to its lowest value. Set xIs potentiometer to 1. Slowly raise the current until the relay picks up. The relay contacts should switch cleanly with no chatter of the contacts, and be relatively quite. The mechanical flag should fall as or just before the contacts operate. Reduce the current slowly and the relay should reset. Repeat this procedure several times to ensure consistency, resetting the mechanical flag after each operation. Pick up tolerance Reset value 5% of Is >80% of Is

Repeat this test for each of the calibration marks of the xIs potentiometer Set the plug bridge to its highest value and repeat above for calibrated values xIs potentiometer. Remove plug from plug bridge and check that the setting is at its highest plug bridge setting.
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2.10

Output Contacts Check that the output contacts close or open as appropriate. Replace the cover and ensure that the cover reset mechanism will reset the mechanical flag. Connect the relay to the system as shown in the application diagram. Replacing any links, wiring, fuses and remove any ct short circuits used during commissioning.

Section 3.

MAINTENANCE

Periodic maintenance is not necessary. However, periodic inspection and test is recommended. This should be carried out every 12 months or more often if the relay is operated frequently or is mounted in poor environmental conditions. Routine testing of the relay can be performed by the secondary injection method, as detailed in the commissioning instructions, Section 2. Mechanical setting should be checked as per Section 4, and if any adjustment is made, then Section 2 should be repeated.

Section 4.
4.1

MECHANICAL SETTINGS

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 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. Contact Type Make (normally open) Break (normally closed) Symbol used on diagrams Normal duty M B

With the armature closed the clearance between the back of the armature and the back stop should be 0.003/0".008". Nominal armature gap open 0.070"/0.080". Nominal armature gap closed 0.070"/0.025"-adjustment by setting screw in armature, lock and varnish after setting.

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4.2

Contact setting Normal duty make and break contacts. With the armature closed onto a 0.012" feeler gauge the make contact should be closed, but should be open using a 0.015" feeler gauge. Force to just close the make contacts 18/23 grams. Make contact gap 0.070"/0.080". Force to just open the break contacts 15/20 grams. Break contact gap 0.060"/0.070". The gap between the top of the armature and the make moving contact should be 0.130 minimum when the flag is down. Relays with four pairs of hands reset contact. It will be necessary to remove the force of the upper contacts from the measuring the appropriate contact force. Also with the flag down the force to just move the armature off the backstop should be 60/80 grams. This force is measured at the end of the armature and is adjusted by the screw which is located between the contact blades near to the contact blocks. Contact settings for: Normal duty make and break short hand reset contacts.

4.3

Mechanical flag setting With the armature closed onto a 0.015" feeler gauge the flag should be free to fall, but should not fall using a 0.020" feeler gauge. Adjustment is made to the catch spring on the flag.

Section 5.
5.1

PROBLEM ANALYSIS

Failure to operate Check diagram for correct input connections. Check value of Is, the value is marked on the module front plate over the plug bridge. The potentiometer (xIs) is a multiplier for the plug setting. Check internal wiring for loose or damaged joints. Flag spring may be distorted holding the armature open. Push rods not correctly located. Check value of potentiometer RV1 (4.7K ohms +10%) and that its value can be adjusted. Check value of R1 (1K ohms +5%). Check continuity of T1 secondary/primary (check both plug taps). Check continuity of relay coil (2640 ohms 10%). Check diodes D1 and D4 on the pcb Zg 0891 for open or short circuit.

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5.2

Operating at the incorrect values Check plug settings, and xIs settings. Check knob on xIs, the dot on the potentiometer skirt should be in line with the setting mark when the potentiometer os rotated fully anticlockwise. Check mechanical settings-see Section 4. Check values and adjustment of potentiometer, this can be damaged if overloads are left on too long. See Publication R6035 for ratings. Current supply not sinusoidal. Inaccurate ammeter.

5.3

Output contacts Contacts making mechanically, but open circuit at case terminals. Check wire diagram. Check connections to module terminal block and relay contacts. Contacts contaminated- these should be cleaned with a burnishing tool, supplied in relay tool kits On on account should knifes, files or abrasive materials be used. Check mechanical settings as per Section 4.

5.3.1

Output contacts not operating mechanically Push rods not correctly located. Check electrical connections. Flag spring may be distorted holding the armature open

Section 6.

SPARES

When ordering spares, quote the full relay model number and any component reference numbers, or briefly describe the parts. Repairs Should the need arise for the equipment to be returned to GEC ALSTHOM T&D Protection & Control Limited 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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Section 7.

COMMISSIONING TEST RECORD

Type MCAG Current Relay Single and Three Phase Site ______________________________ Model No. _________________________ Rating: ___________________________ Diagram __________________________ 1. Pick up check Phase A B C Delete if not applicable 1.1 2. 3. 4. Check reset (drop off) is >80% of Is Check flag indicator Check contact operation Remarks __________ __________ __________ Setting Operate current Circuit ____________________________ Serial No. __________________________ Aux ______________________________ Setting ____________________________

___________________________________ Commissioning Engineer ___________________________________ Date

____________________________________ Customer Witness ____________________________________ Date

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Page 10

REPAIR FORM
Please complete this form and return it to GEC ALSTHOM T&D Protection & Control Limited with the equipment to be repaired. This form may also be used in the case of application queries.

GEC ALSTHOM T&D Protection & Control Limited St. Leonards Works Stafford ST17 4LX, England For: After Sales Service Department Customer Ref: GECA Contract Ref: Date: 1. __________________ __________________ __________________ Model No: _________________ Serial No: _________________

What parameters were in use at the time the fault occurred? AC volts DC volts _____________ Main VT/Test set _____________ Battery/Power supply

AC current _____________ Main CT/Test set Frequency _____________ 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 ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ 5. What did you expect to happen? ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
continued overleaf

Yes/No

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6.

What did happen? ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________

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.

Was there any visual damage? ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________

10. Any other remarks which may be useful: ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________

___________________________________ Signature ___________________________________ Name (in capitals)

____________________________________ Title ____________________________________ Company name

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Publication: R8035F
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